Miniaturized multiple Fourier-horn ultrasonic droplet generators for biomedical applications

Facile Microembossing Process for Microchannel Fabrication for Nanocellulose-Paper-Based Microfluidics

Nanofibrillated cellulose paper (nanopaper) has gained growing interest as one promising substrate material for paper-based microfluidics, thanks to its ultrasmooth surface, high optical transparency, uniform nanofiber matrix with nanoscale porosity, and tunable chemical properties. Recently, research on nanopaper-based microfluidics has quickly advanced; however, the current technique of patterning microchannels on nanopaper (i.e., 3D printing, spray coating, or manual cutting and sticking), that is fundamental for application development, still has some limitations, such as ease-of-contamination, and more importantly, only enabling millimeter-scale channels. This paper reports a facile process that leverages the simple operations of microembossing with the convenient plastic micro-molds, for the first time, patterning nanopaper microchannels downing to 200 μm, which is 4 times better than the existing methods and is time-saving (<45 mins). We also optimized the patterning parameters and provided one quick look-up table as the guideline for application developments. As proof-of-concept, we first demonstrated two fundamental microfluidic devices on nanopaper, the laminar-mixer and droplet generator, and two functional nanopaper-based analytical devices (NanoPADs) for glucose and Rhodamine B (RhB) sensing based on optical colorimetry and surface-enhanced Raman spectroscopy, respectively. The two NanoPADs showed outstanding performance with low limits of detection (2 mM for glucose and 19fM for RhB), which are 1.25× and 500× fold improvement compared to the previously reported values. This can be attributed to our newly developed highly accurate microchannel patterning process that enables high integration and fine-tunability of the NanoPADs along with the superior optical properties of nanopaper.

Nebulization of siRNA for inhalation therapy based on a microfluidic surface acoustic wave platform

The local delivery of therapeutic small interfering RNA or siRNA to the lungs has the potential to improve the prognosis for patients suffering debilitating lung diseases. Recent advances in materials science have been aimed at addressing delivery challenges including biodistribution, bioavailability and cell internalization, but an equally important challenge to overcome is the development of an inhalation device that can deliver the siRNA effectively to the lung, without degrading the therapeutic itself. Here, we report the nebulization of siRNA, either naked siRNA or complexed with polyethyleneimine (PEI) or a commercial transfection agent, using a miniaturizable acoustomicrofluidic nebulization device. The siRNA solution could be nebulised without significant degradation into an aerosol mist with tunable mean aerodynamic diameters of approximately 3 µm, which is appropriate for deep lung deposition via inhalation. The nebulized siRNA was tested for its stability, as well as its toxicity and gene silencing properties using the mammalian lung carcinoma cell line A549, which demonstrated that the gene silencing capability of siRNA is retained after nebulization. This highlights the potential application of the acoustomicrofluidic device for the delivery of efficacious siRNA via inhalation, either for systemic delivery via the alveolar epithelium or local therapeutic delivery to the lung.

Particle Size Analysis in Aerosol-Generating Dental Procedures Using Laser Diffraction Technique

The global outbreak of coronavirus disease 2019 (COVID-19) has raised concerns about the risk of airborne infection during dental treatment. Aerosol-generating dental procedures (AGDP) produce droplets and aerosols, but the details of the risks of COVID-19 transmission in AGDP are not well-understood. By discriminating between droplets and aerosols, we devised a method to measure particle size using laser diffraction analysis and evaluated aerosols generated from dental devices for providing a basis for proper infection control procedures. The droplets and aerosols generated from dental devices were characterized by multimodal properties and a wide range of droplet sizes, with the majority of droplets larger than 50 μm. AGDP emitted few aerosols smaller than 5 μm, which are of concern for pulmonary infections due to airborne transmission. In addition, the use of extraoral suction was found to prevent the spread of aerosols from high-speed dental engines. This study suggests that the risk of aerosol infections is considerably limited in regular dental practice and that current standard precautions, such as mainly focusing on protection against droplet and contact infections, are sufficient. While several cases of airborne transmission of COVID-19 in general clinics and emergency hospitals have been reported, cluster outbreaks in dental clinics have not yet been reported, which may indicate that AGDP does not pose a significant threat in contributing to the spread of SARS-CoV-2.

Spray characteristics of an ultrasonic microdroplet generator with a continuously variable operating frequency

Droplet spraying is utilized in diverse industrial processes and biomedical applications, including nanomaterial synthesis, biomaterial handling, and inhalation drug delivery. Ultrasonic droplet generators transfer energy into bulk liquids using acoustic waves to disrupt the free liquid surface into fine microdroplets. We previously established a method combining ultrasonic actuation, resonant operation, and acoustic wave focusing for efficient spraying of various liquids (e.g., low surface tension fuels, high viscosity inks, and suspensions of biological cells). The microfabricated device comprises a piezoelectric transducer, sample reservoir, and an array of acoustic horn structures terminated by microscale orifices. Orifice size roughly dictates droplet diameter, and a fixed reservoir height prescribes specific device resonant frequencies of operation. Here, we incorporate a continuously variable liquid reservoir height for dynamic adjustment of operating parameters to improve spray efficiency in real-time and potentially tune the droplet size. Computational modeling predicts the system harmonic response for a range of reservoir heights from 0.5 to 3 mm (corresponding to operating frequencies from ∼500 kHz to 2.5 MHz). Nozzle arrays with 10, 20, and 40 μm orifices are evaluated for spray uniformity and stability of the active nozzles, using model predictions to explain the experimental observations.

Tuning the Coupled-Domain Response for Efficient Ultrasonic Droplet Generation

Acoustic microfluidic devices encompass mechanical, fluidic, and electromechanical domains. Complicated multidomain interactions require the consideration of each individual material domain, as well as coupled behaviors to achieve optimal performance. Herein, we report the co-optimization of components comprising an ultrasonic droplet generator to achieve the high-efficiency liquid atomization for operation in the 0.5-2.5-MHz frequency range. Due to the complexity of the real system, simplified 2-D representations of the device are investigated using an experimentally validated finite element analysis model. Ejection modes (i.e., frequencies at which droplet generation is predicted) are distinguished by maxima in the local pressure at the tips of an array of triangular nozzles. Resonance behaviors of the transducer assembly and fluid-filled chamber are examined to establish optimal geometric combinations concerning the chamber pressure field. The analysis identifies how domain geometries affect pressure field uniformity, broadband operation, and tip pressure amplitude. Lower frequency modes are found to focus the acoustic energy at the expense of field uniformity within the nozzle array. Resonance matching yields a nearly threefold increase in maximum attainable tip pressure amplitude. Significantly, we establish a set of design principles for these complex devices, which resembles a classical half-wave transducer, quarter-wave matching layer, and half-wave chamber layered system.

Faraday Waves-Based Integrated Ultrasonic Micro-Droplet Generator and Applications

An in-depth review on a new ultrasonic micro-droplet generator which utilizes megahertz (MHz) Faraday waves excited by silicon-based multiple Fourier horn ultrasonic nozzles (MFHUNs) and its potential applications is presented. The new droplet generator has demonstrated capability for producing micro droplets of controllable size and size distribution and desirable throughput at very low electrical drive power. For comparison, the serious deficiencies of current commercial droplet generators (nebulizers) and the other ultrasonic droplet generators explored in recent years are first discussed. The architecture, working principle, simulation, and design of the multiple Fourier horns (MFH) in resonance aimed at the amplified longitudinal vibration amplitude on the end face of nozzle tip, and the fabrication and characterization of the nozzles are then described in detail. Subsequently, a linear theory on the temporal instability of Faraday waves on a liquid layer resting on the planar end face of the MFHUN and the detailed experimental verifications are presented. The linear theory serves to elucidate the dynamics of droplet ejection from the free liquid surface and predict the vibration amplitude onset threshold for droplet ejection and the droplet diameters. A battery-run pocket-size clogging-free integrated micro droplet generator realized using the MFHUN is then described. The subsequent report on the successful nebulization of a variety of commercial pulmonary medicines against common diseases and on the experimental antidote solutions to cyanide poisoning using the new droplet generator serves to support its imminent application to inhalation drug delivery.

Pulmonary monoclonal antibody delivery via a portable microfluidic nebulization platform

Nebulizers have considerable advantages over conventional inhalers for pulmonary drug administration, particularly because they do not require coordinated breath actuation to generate and deliver the aerosols. Nevertheless, besides being less amenable to miniaturization and hence portability, some nebulizers are prone to denature macromolecular drugs due to the large forces generated during aerosolization. Here, we demonstrate a novel portable acoustomicrofluidic device capable of nebulizing epidermal growth factor receptor (EGFR) monoclonal antibodies into a fine aerosol mist with a mass median aerodynamic diameter of approximately 1.1 μm, optimal for deep lung deposition via inhalation. The nebulized monoclonal antibodies were tested for their stability, immunoactivity, and pharmacological properties, which confirmed that nebulization did not cause significant degradation of the antibody. In particular, flow cytometry demonstrated that the antigen binding capability of the antibody is retained and able to reduce phosphorylation in cells overexpressing the EGFR, indicating that the aerosols generated by the device were loaded with stable and active monoclonal antibodies. The delivery of antibodies via inhalation, particularly for the treatment of lung cancer, is thus expected to enhance the efficacy of this protein therapeutic by increasing the local concentration where they are needed.

Faraday instability-based micro droplet ejection for inhalation drug delivery

We report here the technology and the underlying science of a new device for inhalation (pulmonary) drug delivery which is capable of fulfilling needs unmet by current commercial devices. The core of the new device is a centimeter-size clog-free silicon-based ultrasonic nozzle with multiple Fourier horns in resonance at megahertz (MHz) frequency. The dramatic resonance effect among the multiple horns and high growth rate of the MHz Faraday waves excited on a medicinal liquid layer together facilitate ejection of monodisperse droplets of desirable size range (2-5 µm) at low electrical drive power (<1.0 W). The small nozzle requiring low drive power has enabled realization of a pocket-size (8.6 × 5.6 × 1.5 cm³) ultrasonic nebulizer. A variety of common pulmonary drugs have been nebulized using the pocket-size unit with desirable aerosol sizes and output rate. These results clearly provide proof-of-principle for the new device and confirm its potential for commercialization.

Ejection of uniform micrometer-sized droplets from Faraday waves on a millimeter-sized water drop

This Letter reports the first observation and theoretical analysis of a new phenomenon: one large spherical water drop ejecting simultaneously a very large number of monodisperse microdroplets. An ultrasonic nozzle with multiple-Fourier horns in resonance enables controlled excitation of megahertz Faraday waves on the free water surface. The temporal instability of such waves leads to the ejection of 3.5-4.4  μm monodisperse droplets at a high rate (>4.0×10(7)  droplets/sec). This is in stark contrast to the Rayleigh-Plateau instability, which ejects one droplet at a time.