Microfluidic on-demand droplet merging using surface acoustic waves

An Acoustofluidic Picoinjector

Droplet microfluidics has emerged as a valuable technology for a multitude of chemical and biomedical applications, offering the capability to create independent microenvironments for high-throughput assays. Central to numerous droplet microfluidic applications is the picoinjection of materials into individual droplets, yet existing picoinjection methods often exhibit high power requirements, lack biocompatibility, and/or suffer from limited controllability. Here, we present an acoustofluidic picoinjector that generates acoustic pressure at the droplet interface to enable on-demand, energy-efficient, and biocompatible injection at high precision. We validate our platform by performing acid-base titrations by iteratively injecting picoliter volume reagents into droplets to induce pH transitions detectable by color change in solution. Additionally, we demonstrate the versatility of the acoustofluidic picoinjector in the synthesis of metallic nanoparticles, yielding highly monodisperse and reproducible particle morphologies compared to conventional bulk-phase techniques. By facilitating controlled delivery of reagents or biological samples with unparalleled accuracy, acoustofluidic picoinjection broadens the utility of droplet microfluidics for a myriad of applications in chemical and biological research.

Digital Microfluidics for Sample Preparation in Low-Input Proteomics

Low-input proteomics, also referred to as micro- or nanoproteomics, has become increasingly popular as it allows one to elucidate molecular processes in rare biological materials. A major prerequisite for the analytics of minute protein amounts, e.g., derived from low cell numbers, down to single cells, is the availability of efficient sample preparation methods. Digital microfluidics (DMF), a technology allowing the handling and manipulation of low liquid volumes, has recently been shown to be a powerful and versatile tool to address the challenges in low-input proteomics. Here, an overview is provided on recent advances in proteomics sample preparation using DMF. In particular, the capability of DMF to isolate proteomes from cells and small model organisms, and to perform all necessary chemical sample preparation steps, such as protein denaturation and proteolytic digestion on-chip, are highlighted. Additionally, major prerequisites to making these steps compatible with follow-up analytical methods such as liquid chromatography-mass spectrometry will be discussed.

High-Efficiency Interdigitated Electrode-Based Droplet Merger for Enabling Error-Free Droplet Microfluidic Systems

Merging two droplets into a droplet to add and mix two contents is one of the common droplet microfluidic functions with droplet generation and sorting, performing broad ranges of biological and chemical assays in droplets. However, traditional droplet-merging techniques often encounter unsynchronized droplets, causing overmerging or mis-merging, and unwanted merging outside of the desired zone. This is more severe when the incoming droplets to be merged are polydisperse in their sizes, often observed in assays that require long-term incubation, elevated-temperature, and/or multiple droplet processing steps. Here, we developed an interdigitated electrode (IDE)-based droplet merger consisting of a droplet autosynchronizing channel and a merging channel. The autosynchronizing channel provides >95% merging efficiency even when 20% polydispersity in the droplet size exists. The highly localized and enhanced dielectrophoretic force generated by the IDEs on the channel bottom allows droplet merging at an extremely low voltage (4.5 V) and only locally at the IDE region. A systematic evaluation of how various design and operation parameters of the IDE merger, such as IDE finger dimensions, dielectric coating layer thickness, droplet size, and droplet flow speed impact the performance was conducted. The optimized device showed consistent performance even when operating for up to 100 h consecutively at high throughput (100 droplets/s). The presented technology has been integrated into a droplet microfluidics workflow to test the lytic activities of bacteriophage on bacterial host cells with 100% merging efficiency. We expect this function to be integrated into droplet microfluidic systems performing broad ranges of high-throughput chemical and biological assays.

Evaluation of Acoustophoretic and Dielectrophoretic Forces for Droplet Injection in Droplet-Based Microfluidic Devices

Acoustophoretic forces have been successfully implemented into droplet-based microfluidic devices to manipulate droplets. These acoustophoretic forces in droplet microfluidic devices are typically generated as in acoustofluidic devices through transducer actuation of a piezoelectric substrate such as lithium niobate (LiNbO3), which is inherently accompanied by the emergence of electrical fields. Understanding acoustophoretic versus dielectrophoretic forces produced by electrodes and transducers within active microfluidic devices is important for the optimization of device performance during design iterations. In this case study, we design microfluidic devices with a droplet injection module and report an experimental strategy to deduce the respective contribution of the acoustophoretic versus dielectrophoretic forces for the observed droplet injection. Our PDMS-based devices comprise a standard oil-in-water droplet-generating module connected to a T-junction injection module featuring actuating electrodes. We use two different electrode geometries produced within the same PDMS slab as the droplet production/injection channels by filling low-melting-point metal alloy into channels that template the electrode geometries. When these electrodes are constructed on LiNbO3 as the substrate, they have a dual function as a piezoelectric transducer, which we call embedded liquid metal interdigitated transducers (elmIDTs). To decipher the contribution of acoustophoretic versus dielectrophoretic forces, we build the same devices on either piezoelectric LiNbO3 or nonpiezo active glass substrates with different combinations of physical device characteristics (i.e., elmIDT geometry and alignment) and operate in a range of phase spaces (i.e., frequency, voltage, and transducer polarity). We characterize devices using techniques such as laser Doppler vibrometry (LDV) and infrared imaging, along with evaluating droplet injection for our series of device designs, constructions, and operating parameters. Although we find that LiNbO3 device designs generate acoustic fields, we demonstrate that droplet injection occurs only due to dielectrophoretic forces. We deduce that droplet injection is caused by the coupled dielectrophoretic forces arising from the operation of elmIDTs rather than by acoustophoretic forces for this specific device design. We arrive at this conclusion because equivalent droplet injection occurs without the presence of an acoustic field using the same electrode designs on nonpiezo active glass substrate devices. This work establishes a methodology to pinpoint the major contributing force of droplet manipulation in droplet-based acoustomicrofluidics.

Characteristics of Oil-in-Oil Emulsions under AC Electric Fields

Emulsions have been applied in a number of industries such as pharmaceutics, cosmetics, and food, which are also of great scientific interest. Although aqueous emulsions are commonly used in our daily life, oil-in-oil (o/o) emulsions also play an irreplaceable role in view of their unique physics and complementary applications. In this paper, we investigate typical behaviors of organic droplets surrounded by organic medium (o/o emulsions) with different functional groups controlled by the AC electric field. Droplet behaviors can be catalogued into five types: namely, "no effect", "movement", "deformation", "interface rupture", and "disorder". We identify the key dimensionless number Wee·Ca, combined with the channel geometry, for characterizing the typical behaviors in silicon oil/1,6-hexanediol diacrylate and mineral oil/1,6-hexanediol diacrylate emulsions. Unlike aqueous emulsion, the Maxwell-Wagner relaxation inhibits the electric effect and leads to an effective frequency, ranging from 0.5 to 3 kHz. The increasing viscosity of the droplet facilitates the escalation by promoting the shearing effect under the same flow conditions. Ethylene glycol droplets primarily show the efficient coalescence even at a low Wee·Ca, which is attributed to the attraction of free charges induced by the increasing conductivity. In 1,6-hexanediol diacrylate/silicon oil emulsion, the droplet tends to form a liquid film that expands into the entire channel due to the affinity of the droplet to the channel wall. A variety of elongated columns are observed to oscillate between the electrodes at high voltages. These findings can contribute to understanding the electrohydrodynamic physics in o/o emulsion and controlling droplet behaviors in a fast response, programmable, and high-throughput way. We expect that this droplet manipulation technology can be widely adopted in a broad range of chemical synthesis and biological and material science.

Programmable Control of Nanoliter Droplet Arrays using Membrane Displacement Traps

A unique droplet microfluidic technology enabling programmable deterministic control over complex droplet operations is presented. The platform provides software control over user-defined combinations of droplet generation, capture, ejection, sorting, splitting, and merging sequences to enable the design of flexible assays employing nanoliter-scale fluid volumes. The system integrates a computer vision system with an array of membrane displacement traps capable of performing selected unit operations with automated feedback control. Sequences of individual droplet handling steps are defined through a robust Python-based scripting language. Bidirectional flow control within the microfluidic chips is provided using an H-bridge channel topology, allowing droplets to be transported to arbitrary trap locations within the array for increased operational flexibility. By enabling automated software control over all droplet operations, the system significantly expands the potential of droplet microfluidics for diverse biological and biochemical applications by combining the functionality of robotic liquid handling with the advantages of droplet-based fluid manipulation.

A Comprehensive Review of Surface Acoustic Wave-Enabled Acoustic Droplet Ejection Technology and Its Applications

This review focuses on the development of surface acoustic wave-enabled acoustic drop ejection (SAW-ADE) technology, which utilizes surface acoustic waves to eject droplets from liquids without touching the sample. The technology offers advantages such as high throughput, high precision, non-contact, and integration with automated systems while saving samples and reagents. The article first provides an overview of the SAW-ADE technology, including its basic theory, simulation verification, and comparison with other types of acoustic drop ejection technology. The influencing factors of SAW-ADE technology are classified into four categories: fluid properties, device configuration, presence of channels or chambers, and driving signals. The influencing factors discussed in detail from various aspects, such as the volume, viscosity, and surface tension of the liquid; the type of substrate material, interdigital transducers, and the driving waveform; sessile droplets and fluid in channels/chambers; and the power, frequency, and modulation of the input signal. The ejection performance of droplets is influenced by various factors, and their optimization can be achieved by taking into account all of the above factors and designing appropriate configurations. Additionally, the article briefly introduces the application scenarios of SAW-ADE technology in bioprinters and chemical analyses and provides prospects for future development. The article contributes to the field of microfluidics and lab-on-a-chip technology and may help researchers to design and optimize SAW-ADE systems for specific applications.

AC-electric-field-controlled multi-component droplet coalescence at microscale

Droplet coalescence with fast response, high controllability and monodispersity has been widely investigated in industrial production and bioengineering. Especially for droplets with multiple components, programmable manipulation of such droplets is crucial for practical applications. However, precise control of the dynamics can be challenging, owing to the complex boundaries and the interfacial and fluidic properties. AC electric fields, with their fast response and high flexibility, have attracted our interest. We design and fabricate an improved flow-focusing microchannel configuration together with a non-contact type of electrode featuring asymmetric geometries, based on which we conduct systematic investigations of the AC-electric-field-controlled coalescence of multi-component droplets at the microscale. Parameters such as flow rates, component ratio, surface tension, electric permittivity and conductivity were given our attention. The results show that droplet coalescence in different flow parameters can be achieved in milliseconds by adjusting the electrical conditions, which shows high controllability. Specifically, both the coalescence region and reaction time can be adjusted by a combination of applied voltage and frequency, and unique merging phenomena have appeared. One is contact coalescence with the approach of paired droplets, while the other is squeezing coalescence, which occurs in the start position and promotes the merging process. The fluid properties, such as the electric permittivity, conductivity and surface tension, present a significant influence on merging behavior. The increasing relative dielectric constant leads to a dramatic reduction of the start merging voltage from the original 250 V to 30 V. The range of effective voltage for coalescence decreases with the addition of surfactant, offering a stricter and yet higher selectivity on electrical conditions, about 1500 V. The conductivity presents a negative correlation with the start merging voltage due to the reduction of the dielectric stress, from 400 V to 1500 V. Finally, we achieve the precise fabrication process of the Janus droplet via implementation of the proposed method, where the components of the droplets and the coalescence conditions are well controlled. Our results can serve as a potent methodology to decipher the physics of multi-component droplet electro-coalescence and contribute to applications in chemical synthesis, bioassay and material synthesis.

A novel droplet-based approach to study phase transformations in lyotropic liquid crystalline systems

HYPOTHESIS

Lyotropic liquid crystals (LLC) and their phase transformations in response to stimuli have gathered much interest for controlled and 'on-demand' drug applications. Bulk methods of preparation impose limitations on studying the transformations, especially induced by compositional changes, such as enzymatic changes to lipid structure. Here we hypothesise that controlled microfluidic production and coalescence of dissimilar aqueous and lipid droplets emulsified in a third mutually immiscible liquid will provide a new approach to the spatio-temporal study of structure formation in lyotropic liquid crystalline materials.

EXPERIMENTS

Separate lipid and aqueous droplets, dispersed in a fluorocarbon oil were generated using a microfluidic format. The chip, prepared as a hybrid polydimethylsiloxane (PDMS) and glass microfluidic device, was constructed to enable in-situ acquisition of time-resolved synchrotron small angle X-ray scattering (SAXS) and crossed polarised light microscopy of the coalesced droplets to determine the structures present during aging.

FINDINGS

Janus-like droplets formed upon coalesce, with distinct lipid and aqueous portions with a gradient between the two sides of the merged droplet. SAXS and polarised light microscopy revealed a progression of mesophases as the lipid portion was hydrated by the aqueous portion via the diffusion limited interface which separated the portions. Thus demonstrating, on a droplet scale, a new approach for studying the phase transformation kinetics and identification of non-equilibrium phase in droplet-based lyotropic liquid systems.

Ultrasonic surface acoustic wave-assisted separation of microscale droplets with varying acoustic impedance

In droplet-based microfluidic platforms, precise separation of microscale droplets of different chemical composition is increasingly necessary for high-throughput combinatorial chemistry in drug discovery and screening assays. A variety of droplet sorting methods have been proposed, in which droplets of the same kind are translocated. However, there has been relatively less effort in developing techniques to separate the uniform-sized droplets of different chemical composition. Most of the previous droplet sorting or separation techniques either rely on the droplet size for the separation marker or adopt on-demand application of a force field for the droplet sorting or separation. The existing droplet microfluidic separation techniques based on the in-droplet chemical composition are still in infancy because of the technical difficulties. In this study, we propose an acoustofluidic method to simultaneously separate microscale droplets of the same volume and dissimilar acoustic impedance using ultrasonic surface acoustic wave (SAW)-induced acoustic radiation force (ARF). For extensive investigation on the SAW-induced ARF acting on both cylindrical and spherical droplets, we first performed a set of the droplet sorting experiments under varying conditions of acoustic impedance of the dispersed phase fluid, droplet velocity, and wave amplitude. Moreover, for elucidation of the underlying physics, a new dimensionless number AR_D was introduced, which was defined as the ratio of the ARF to the drag force acting on the droplets. The experimental results were comparatively analyzed by using a ray acoustics approach and found to be in good agreement with the theoretical estimation. Based on the findings, we successfully demonstrated the simultaneous separation of uniform-sized droplets of the different acoustic impedance under continuous application of the acoustic field in a label-free and detection-free manner. Insomuch as on-chip, precise separation of multiple kinds of droplets is critical in many droplet microfluidic applications, the proposed acoustofluidic approach will provide new prospects for microscale droplet separation.

Droplet microfluidics for CTC-based liquid biopsy: a review

Circulating tumor cells (CTCs) are important biomarkers of liquid biopsy. The number and heterogeneity of CTCs play an important role in cancer diagnosis and personalized medicine. However, owing to the low-abundance biomarkers of CTCs, conventional assays are only able to detect CTCs at the population level. Therefore, there is a pressing need for a highly sensitive method to analyze CTCs at the single-cell level. As an important branch of microfluidics, droplet microfluidics is a high-throughput and sensitive single-cell analysis platform for the quantitative detection and heterogeneity analysis of CTCs. In this review, we focus on the quantitative detection and heterogeneity analysis of CTCs using droplet microfluidics. Technologies that enable droplet microfluidics, particularly high-throughput droplet generation and high-efficiency droplet manipulation, are first discussed. Then, recent advances in detecting and analyzing CTCs using droplet microfluidics from the different aspects of nucleic acids, proteins, and metabolites are introduced. The purpose of this review is to provide guidance for the continued study of droplet microfluidics for CTC-based liquid biopsy.

Merging microfluidics with luminescence immunoassays for urgent point-of-care diagnostics of COVID-19

The Coronavirus disease 2019 (COVID-19) outbreak has urged the establishment of a global-wide rapid diagnostic system. Current widely-used tests for COVID-19 include nucleic acid assays, immunoassays, and radiological imaging. Immunoassays play an irreplaceable role in rapidly diagnosing COVID-19 and monitoring the patients for the assessment of their severity, risks of the immune storm, and prediction of treatment outcomes. Despite of the enormous needs for immunoassays, the widespread use of traditional immunoassay platforms is still limited by high cost and low automation, which are currently not suitable for point-of-care tests (POCTs). Microfluidic chips with the features of low consumption, high throughput, and integration, provide the potential to enable immunoassays for POCTs, especially in remote areas. Meanwhile, luminescence detection can be merged with immunoassays on microfluidic platforms for their good performance in quantification, sensitivity, and specificity. This review introduces both homogenous and heterogenous luminescence immunoassays with various microfluidic platforms. We also summarize the strengths and weaknesses of the categorized methods, highlighting their recent typical progress. Additionally, different microfluidic platforms are described for comparison. The latest advances in combining luminescence immunoassays with microfluidic platforms for POCTs of COVID-19 are further explained with antigens, antibodies, and related cytokines. Finally, challenges and future perspectives were discussed.

Acoustics-Controlled Microdroplet and Microbubble Fusion and Its Application in the Synthesis of Hydrogel Microspheres

Droplet fusion technology is a key technology for many droplet-based biochemical medical applications. By integrating a symmetrical flow channel structure, we demonstrate an acoustics-controlled fusion method of microdroplets using surface acoustic waves. Different kinds of microdroplets can be staggered and ordered in the symmetrical flow channel, proving the good arrangement effect of the microfluidic chip. This method can realize not only the effective fusion of microbubbles but also the effective fusion of microdroplets of different sizes without any modification. Further, we investigate the influence of the input frequency and peak-to-peak value of the driving voltage on microdroplets fusion, giving the effective fusion parameter conditions of microdroplets. Finally, this method is successfully used in the preparation of hydrogel microspheres, offering a new platform for the synthesis of hydrogel microspheres.

Design of interdigitated transducers for acoustofluidic applications

Interdigitated transducers (IDTs) were originally designed as delay lines for radars. Half a century later, they have found new life as actuators for microfluidic systems. By generating strong acoustic fields, they trigger nonlinear effects that enable pumping and mixing of fluids, and moving particles without contact. However, the transition from signal processing to actuators comes with a range of challenges concerning power density and spatial resolution that have spurred exciting developments in solid-state acoustics and especially in IDT design. Assuming some familiarity with acoustofluidics, this paper aims to provide a tutorial for IDT design and characterization for the purpose of acoustofluidic actuation. It is targeted at a diverse audience of researchers in various fields, including fluid mechanics, acoustics, and microelectronics.

Acoustic Manipulation of Intraocular Particles

Various conditions cause dispersions of particulate matter to circulate inside the anterior chamber of a human eye. These dispersed particles might reduce visual acuity or promote elevation of intraocular pressure (IOP), causing secondary complications such as particle related glaucoma, which is a major cause of blindness. Medical and surgical treatment options are available to manage these complications, yet preventive measures are not currently available. Conceptually, manipulating these dispersed particles in a way that reduces their negative impact could prevent these complications. However, as the eye is a closed system, manipulating dispersed particles in it is challenging. Standing acoustic waves have been previously shown to be a versatile tool for manipulation of bioparticles from nano-sized extracellular vesicles up to millimeter-sized organisms. Here we introduce for the first time a novel method utilizing standing acoustic waves to noninvasively manipulate intraocular particles inside the anterior chamber. Using a cylindrical acoustic resonator, we show ex vivo manipulation of pigmentary particles inside porcine eyes. We study the effect of wave intensity over time and rule out temperature changes that could damage tissues. Optical coherence tomography and histologic evaluations show no signs of damage or any other side effect that could be attributed to acoustic manipulation. Finally, we lay out a clear pathway to how this technique can be used as a non-invasive tool for preventing secondary glaucoma. This concept has the potential to control and arrange intraocular particles in specific locations without causing any damage to ocular tissue and allow aqueous humor normal outflow which is crucial for maintaining proper IOP levels.

Trapping of Aqueous Droplets under Surface Acoustic Wave-Driven Streaming in Oil-Filled Microwells

Microwell arrays are ideal platforms for cell culturing, cell separation, and low-volume liquid handling. The ability to manipulate droplets in microwells could open up the opportunity for developing new biochemical assays. Here, we study the trapping of aqueous droplets in an oil-filled microwell driven by the application of nanometer amplitude vibrations called surface acoustic waves (SAW). We elucidate the dynamics of the droplet within the vortex toward the final trapping location and the physics of the trapping phenomenon using a theoretical model by considering the relevant forces. Our study revealed that the combined effect of acoustic radiation and hydrodynamic forces leads to droplet migration and trapping. We demarcate the trapping and nontrapping regimes in terms of the minimum critical input power required for the trapping of droplets of different sizes and densities. We find that the critical power varies as the square of the droplet size and is higher for a denser droplet. The effects of input power and droplet size on the trapping location and trapping time are also studied.

Manipulation and control of droplets on surfaces in a homogeneous electric field

A method to manipulate and control droplets on a surface is presented. The method is based on inducing electric dipoles inside the droplets using a homogeneous external electric field. It is shown that the repulsive dipole force efficiently suppresses the coalescence of droplets moving on a liquid-infused surface (LIS). Using a combination of experiments, numerical computations and semi-analytical models, the dependence of the repulsion force on the droplet volumes, the distance between the droplets and the electric field strength is revealed. The method allows to suppress coalescence in complex multi-droplet flows and is real-time adaptive. When the electric field strength exceeds a critical value, tip streaming from the droplets sets in. Based on that, it becomes possible to withdraw minute samples from an array of droplets in a parallel process.

Control of droplet coalescence is a major challenge of droplet microfluidics. Here, the authors show that homogenous external electric field can induce dipoles inside droplets, which can be used to withdraw samples from an array of droplets.

Active single cell encapsulation using SAW overcoming the limitations of Poisson distribution

We demonstrate the use of an acoustic device to actively encapsulate single red blood cells into individual droplets in a T-junction. We compare the active encapsulation with the passive encapsulation depending on the number of loaded cells as well as the created droplet volumes. This method overcomes the Poisson limitation statistical loading of cells for the passive encapsulation. In our experiments we reach a single cell encapsulation efficiency of 97.9 ± 2.1% at droplet formation rates exceeding 15 Hz.

Acoustic valves in microfluidic channels for droplet manipulation

A novel concept of using acoustic valves in microfluidic channels is reported in this work for the first time. An acoustic valve is a controllable virtual barrier constructed with focused acoustic fields, which can control droplets into different branch channels or block and then release them to specific target channels. Compared with other droplet sorting devices using a surface acoustic wave, acoustic valves do not use an acoustic field to drive droplets but only block branch channels. Compared with other sorting methods, such as using dielectric and magnetic forces, acoustic valves do not need a high voltage or target sample modification. As a non-contact and low-damage manipulation method with minimal requirements for target samples, the use of acoustic valve is suitable for microfluidic applications like sorting and manipulation in biochemical experiments, especially those involving optical observation, fluorescence testing, and chemical reactions.

The Peculiarities of the Acoustic Waves of Zero-Order Focusing in Lithium Niobate Plate

In this research, beam focusing in lithium niobate plate was studied for fundamental anti-symmetric (A0) and symmetric (S0) Lamb waves, and the shear-horizontal (SH0) wave of zero-order. Using the finite element method, appropriate configuration of the interdigital transducer with arc-like electrodes was modeled accounting for the anisotropy of the slowness curves and dispersion of the modes in the plate. Profiles of the focalized acoustic beams generated by the proposed transducer were theoretically analyzed. Based on the result of the analysis, relevant delay lines were fabricated and transfer functions (insertion loss) of the line were measured for SH0 wave in YX-lithium niobate plate. Using an electron scanning microscope, distribution of the electric fields of the same wave were visualized. The results of this study may be useful for hybrid devices and sensors combining nano and acoustoelectronic principles.

Computer simulation of submicron fluid flows in microfluidic chips and their applications in food analysis

In recent years, countries around the world have maintained a zero-tolerance attitude toward safety problems in the food industry. In order to ensure human health, a fast, sensitive, and high-throughput analysis of food contaminants is necessary to ensure safe food products on the market. Microfluidics, as a high-efficiency and sensitive detection technology, has many advantages in the detection of food contaminants, including foodborne pathogens, pesticides, heavy metal ions, toxic substances, and so forth, especially in conjunction with a variety of submicron fluid driving methods, making food detection and analysis more efficient and accurate. This review introduces the principle of submicron fluid driving modes and discusses the driving simulation of submicron fluid in microfluidic chips. In addition, the latest developments in the application of simulation in food analysis from 2006 to 2020 are discussed, and the computer simulation of submicron fluid flow in microfluidic chips and its application and development trend in food analysis are also highlighted. The review indicates that microfluidic technology, using numerical simulation as an auxiliary tool, combined with traditional methods has greatly improved the detection and analysis of food products. In addition, microfluidics combined with a variety of control methods embodies the ability of specific, multifunctional, and sensitive detection and analysis of food products. The development of high-sensitivity, high-throughput, portable, integrated microfluidic chips will enable the technology to be applied in practice.

Microfluidic enhancement of self-assembly systems

Dynamic, kinetically-controlled, self-assembly processes are commonly observed in nature and are capable of creating intricate, functional architectures from simple precursors. However, notably, much of the research into molecular self-assembly has been performed using conventional bulk techniques where the resultant species are dictated by thermodynamic stability to yield relatively simple assemblies. Whereas, the environmental control offered by microfluidic systems offers methods to achieve non-equilibrium reaction conditions capable of increasingly sophisticated self-assembled structures. Alterations to the immediate microenvironment during the assembly of the molecules is possible, providing the basis for kinetically-controlled assembly. This review examines the key mechanism offered by microfluidic systems and the architectures required to access them. The mechanisms include diffusion-led mixing, shear gradient alignment, spatial and temporal confinement, and structural templates in multiphase systems. The works are selected and categorised in terms of the microfluidic approaches taken rather than the chemical constructs which are formed.

Universal Plasma Jet for Droplet Manipulation on a PDMS Surface towards Wall-Less Scaffolds

Droplet manipulation is important in the fields of engineering, biology, chemistry, and medicine. Many techniques, such as electrowetting and magnetic actuation, have been developed for droplet manipulation. However, the fabrication of the manipulation platform often takes a long time and requires well-trained skills. Here we proposed a novel method that can directly generate and manipulate droplets on a polymeric surface using a universal plasma jet. One of its greatest advantages is that the jet can tremendously reduce the time for the platform fabrication while it can still perform stable droplet manipulation with controllable droplet size and motion. There are two steps for the proposed method. First, the universal plasma jet is set in plasma mode for modifying the manipulation path for droplets. Second, the jet is switched to air-jet mode for droplet generation and manipulation. The jetted air separates and pushes droplets along the plasma-treated path for droplet generation and manipulation. According to the experimental results, the size of the droplet can be controlled by the treatment time in the first step, i.e., a shorter treatment time of plasma results in a smaller size of the droplet, and vice versa. The largest and the smallest sizes of the generated droplets in the results are about 6 µL and 0.1 µL, respectively. Infrared spectra of absorption on the PDMS surfaces with and without the plasma treatment are investigated by Fourier-transform infrared spectroscopy. Tests of generating and mixing two droplets on a PDMS surface are successfully achieved. The aging effect of plasma treatment for the proposed method is also discussed. The proposed method provides a simple, fast, and low-cost way to generate and manipulate droplets on a polymeric surface. The method is expected to be applied to droplet-based cell culture by manipulating droplets encapsulating living cells and towards wall-less scaffolds on a polymeric surface.

Recent advances in droplet microfluidics for enzyme and cell factory engineering

Enzymes and cell factories play essential roles in industrial biotechnology for the production of chemicals and fuels. The properties of natural enzymes and cells often cannot meet the requirements of different industrial processes in terms of cost-effectiveness and high durability. To rapidly improve their properties and performances, laboratory evolution equipped with high-throughput screening methods and facilities is commonly used to tailor the desired properties of enzymes and cell factories, addressing the challenges of achieving high titer and the yield of the target products at high/low temperatures or extreme pH, in unnatural environments or in the presence of unconventional media. Droplet microfluidic screening (DMFS) systems have demonstrated great potential for exploring vast genetic diversity in a high-throughput manner (>10⁶/h) for laboratory evolution and have been increasingly used in recent years, contributing to the identification of extraordinary mutants. This review highlights the recent advances in concepts and methods of DMFS for library screening, including the key factors in droplet generation and manipulation, signal sources for sensitive detection and sorting, and a comprehensive summary of success stories of DMFS implementation for engineering enzymes and cell factories during the past decade.

Coalescence of Droplets in a Microwell Driven by Surface Acoustic Waves

Microwell arrays are amongst the most commonly used platforms for biochemical assays. However, the coalescence of droplets that constitute the dispersed phase of suspensions housed within microwells has not received much attention to date. Herein, we study the coalescence of droplets in a two-phase system in a microwell driven by surface acoustic waves (SAWs). The microwell structure, together with symmetric exposure to SAW irradiation, coupled from beneath the microwell via a piezoelectric substrate, gives rise to the formation of a pair of counter-rotating vortices that enable droplet transport, trapping, and coalescence. We elucidate the physics of the coalescence phenomenon using a scaling analysis of the relevant forces, namely, the acoustic streaming-induced drag force, the capillary and viscous forces associated with the drainage of the thin continuous phase film between the droplets and the van der Waals attraction force. We confirm that droplet-droplet interface contact is established through the formation of a liquid bridge, whose neck radius grows linearly in time in the preceding viscous regime and proportionally with the square root of time in the subsequent inertial regime. Further, we investigate the influence of the input SAW power and droplet size on the film drainage time and demarcate the coalescence and non-coalescence regimes to derive a criterion for the onset of coalescence. The distinct deformation patterns observed for a pair of contacting droplets in both the regimes are elucidated and the possibility for driving concurrent coalescence of multiple droplets is demonstrated. We expect the study will find relevance in the demulsification of immiscible phases and the mixing of samples/reagents within microwells for a variety of biochemical applications.

Acoustofluidic generation of droplets with tunable chemical concentrations

The dynamic control of the chemical concentration within droplets is required in numerous droplet microfluidic applications. Here, we propose an acoustofluidic method for the generation of a library of aqueous droplets with the desired chemical concentrations in a continuous oil phase. Surface acoustic waves produced by a focused interdigital transducer interact with two parallel laminar streams with different chemical compositions. Coupling the acoustic waves with the flow streams results in the controlled acoustofluidic mixing of the aqueous solutions through the formation of acoustic streaming flow-induced microvortices. The mixed streams are split at a bifurcation, and one of the streams with a precisely controlled chemical concentration is fed into a T-junction to produce droplets with tunable chemical concentrations. The periodic acoustofluidic mixing of the aqueous streams enables the generation of a droplet library with a well-defined inter-droplet concentration gradient. The proposed method is a promising tool for the on-chip dynamic control of in-droplet chemical concentrations and for next-generation droplet microfluidic applications.

Construction of core-shell microcapsules via focused surface acoustic wave microfluidics

The ability to construct core-shell microcapsules has the potential to shift the paradigm in the development of new delivery systems for nutrients, cosmetics, and drugs. In this work, we demonstrate an application of focused surface acoustic wave (FSAW) microfluidics to produce microcapsules with a core-shell structure using one or two focused interdigital transducers (FIDTs) on the microfluidic device. Solid particles or liquid microdroplets without any special modification in multiphase laminar flow are driven by the acoustic radiation force arising from the FSAW, and cross the oil/water interface back and forth, which is not only suitable for generation of core-shell microcapsules with solid cores but also used for coating an aqueous microdroplet core with an oil shell. On this basis, more FIDTs can be added to the device to manufacture more layers of microcapsules if needed. Single-layer, two-layer, or even multi-layer microcapsules can be selectively fabricated. This work provides a promising and robust platform to construct core-shell microcapsules via FSAW microfluidics, which are suitable for a wide range of applications.

One Cell, One Drop, One Click: Hybrid Microfluidics for Mammalian Single Cell Isolation

Generating a stable knockout cell line is a complex process that can take several months to complete. In this work, a microfluidic method that is capable of isolating single cells in droplets, selecting successful edited clones, and expansion of these isoclones is introduced. Using a hybrid microfluidics method, droplets in channels can be individually addressed using a co-planar electrode system. In the hybrid microfluidics device, it is shown that single cells can be trapped and subsequently encapsulate them on demand into pL-sized droplets. Furthermore, droplets containing single cells are either released, kept in the traps, or merged with other droplets by the application of an electric potential to the electrodes that is actuated through an in-house user interface. This high precision control is used to successfully sort and recover single isoclones to establish monoclonal cell lines, which is demonstrated with a heterozygous NCI-H1299 lung squamous cell population resulting from loss-of-function eGFP and RAF1 gene knockout transfections.

Multiphase flow in microfluidics: From droplets and bubbles to the encapsulated structures

Microfluidic technologies have a unique ability to control more precisely and effectively on two-phase flow systems in comparison with macro systems. Controlling the size of the droplets and bubbles has led to an ever-increasing expansion of this technology in two-phase systems. Liquid-liquid and gas-liquid two-phase flows because of their numerous applications in different branches such as reactions, synthesis, emulsions, cosmetic, food, drug delivery, etc. have been the most critical two-phase flows in microfluidic systems. This review highlights recent progress in two-phase flows in microfluidic devices. The fundamentals of two-phase flows, including some essential dimensionless numbers, governing equations, and some most well-known numerical methods are firstly introduced, followed by a review of standard methods for producing segmented flows such as emulsions in microfluidic systems. Then various encapsulated structures, a common two-phase flow structure in microfluidic devices, and different methods of their production are reviewed. Finally, applications of two-phase microfluidic flows in drug-delivery, biotechnology, mixing, and microreactors are briefly discussed.

The complexity of surface acoustic wave fields used for microfluidic applications

Using surface acoustic waves (SAW) for the agitation and manipulation of fluids and immersed particles or cells in lab-on-a-chip systems has been state of the art for several years. Basic tasks comprise fluid mixing, atomization of liquids as well as sorting and separation (or trapping) of particles and cells, e.g. in so-called acoustic tweezers. Even though the fundamental principles governing SAW excitation and propagation on anisotropic, piezoelectric substrates are well-investigated, the complexity of wave field effects including SAW diffraction, refraction and interference cannot be comprehensively simulated at this point of time with sufficient accuracy. However, the design of microfluidic actuators relies on a profound knowledge of SAW propagation, including superposition of multiple SAWs, to achieve the predestined functionality of the devices. Here, we present extensive experimental results of high-resolution analysis of the lateral distribution of the complex displacement amplitude, i.e. the wave field, alongside with the electrical S-parameters of the generating transducers. These measurements were carried out and are compared in setups utilizing travelling SAW (tSAW) excited by single interdigital transducer (IDT), standing SAW generated between two IDTs (1DsSAW, 1D acoustic tweezers) and between two pairs of IDTs (2DsSAW, 2D acoustic tweezers) with different angular alignment in respect to pure Rayleigh mode propagation directions and other practically relevant orientations. For these basic configurations, typically used to drive SAW-based microfluidics, the influence of common SAW phenomena including beam steering, coupling coefficient dispersion and diffraction on the resultant wave field is investigated. The results show how tailoring of the acoustic conditions, based on profound knowledge of the physical effects, can be achieved to finally realize a desired behavior of a SAW-based microacoustic-fluidic system.

Programmable µChopper Device with On-Chip Droplet Mergers for Continuous Assay Calibration

While droplet-based microfluidics is a powerful technique with transformative applications, most devices are passively operated and thus have limited real-time control over droplet contents. In this report, an automated droplet-based microfluidic device with pneumatic pumps and salt water electrodes was developed to generate and coalesce up to six aqueous-in-oil droplets (2.77 nL each). Custom control software combined six droplets drawn from any of four inlet reservoirs. Using our μChopper method for lock-in fluorescence detection, we first accomplished continuous linear calibration and quantified an unknown sample. Analyte-independent signal drifts and even an abrupt decrease in excitation light intensity were corrected in real-time. The system was then validated with homogeneous insulin immunoassays that showed a nonlinear response. On-chip droplet merging with antibody-oligonucleotide (Ab-oligo) probes, insulin standards, and buffer permitted the real-time calibration and correction of large signal drifts. Full calibrations (LOD_conc = 2 ng mL⁻¹ = 300 pM; LOD_amt = 5 amol) required <1 min with merely 13.85 nL of Ab-oligo reagents, giving cost-savings 160-fold over the standard well-plate format while also automating the workflow. This proof-of-concept device—effectively a microfluidic digital-to-analog converter—is readily scalable to more droplets, and it is well-suited for the real-time automation of bioassays that call for expensive reagents.

Image-Based Single Cell Sorting Automation in Droplet Microfluidics

The recent boom in single-cell omics has brought researchers one step closer to understanding the biological mechanisms associated with cell heterogeneity. Rare cells that have historically been obscured by bulk measurement techniques are being studied by single cell analysis and providing valuable insight into cell function. To support this progress, novel upstream capabilities are required for single cell preparation for analysis. Presented here is a droplet microfluidic, image-based single-cell sorting technique that is flexible and programmable. The automated system performs real-time dual-camera imaging (brightfield & fluorescent), processing, decision making and sorting verification. To demonstrate capabilities, the system was used to overcome the Poisson loading problem by sorting for droplets containing a single red blood cell with 85% purity. Furthermore, fluorescent imaging and machine learning was used to load single K562 cells amongst clusters based on their instantaneous size and circularity. The presented system aspires to replace manual cell handling techniques by translating expert knowledge into cell sorting automation via machine learning algorithms. This powerful technique finds application in the enrichment of single cells based on their micrographs for further downstream processing and analysis.

Advances in Micromanipulation Actuated by Vibration-Induced Acoustic Waves and Streaming Flow

The use of vibration and acoustic characteristics for micromanipulation has been prevalent in recent years. Due to high biocompatibility, non-contact operation, and relatively low cost, the micromanipulation actuated by the vibration-induced acoustic wave and streaming flow has been widely applied in the sorting, translating, rotating, and trapping of targets at the submicron and micron scales, especially particles and single cells. In this review, to facilitate subsequent research, we summarize the fundamental theories of manipulation driven by vibration-induced acoustic waves and streaming flow. These methods are divided into two types: actuated by the acoustic wave, and actuated by the steaming flow induced by vibrating geometric structures. Recently proposed representative vibroacoustic-driven micromanipulation methods are introduced and compared, and their advantages and disadvantages are summarized. Finally, prospects are presented based on our review of the recent advances and developing trends.

Microfluidic Valves for Selective on-Chip Droplet Splitting at Multiple Sites

We describe a microfluidic system for control of droplet division at two locations using a T-junction and expansion channel which are placed one after another. Droplets generated at a standard T-junction are introduced into the droplet division section of the microchannel. In the first set of experiments, the droplet division section consists of two consecutive identical T-junctions branching from the main channel. With this geometry, we were able to produce daughter droplets only at the first junction while there was no droplet division at the second junction. Resistive network analysis is used to redesign the microchannel geometry with an expansion channel in place of the second junction, to have the same quantity of flow entering in both the junctions. We observed five different regimes of droplet breakup, namely, (1) no droplet breakup in both junctions, (2) droplet breakup in the first junction, (3) droplet breakup in both junctions with higher daughter droplet volume in the first junction, (4) daughter droplet volume higher in the second junction, and (5) intermittent droplet breakup in both the junctions. Under specific flow conditions, droplet interaction with both the junctions is similar. We then showed design requirements for location of microvalves, simulated by deformation of the main channel wall and by experiments to break the droplet.

On-demand sample injection: combining acoustic actuation with a tear-drop shaped nozzle to generate droplets with precise spatial and temporal control

An on-demand droplet injection method for controlled delivery of nanolitre-volume liquid samples to scientific instruments for subsequent analysis is presented. We employ pulsed focussed surface acoustic waves (SAW) to eject droplets from an enclosed microfluidic channel into an open environment. The 3D position of individual droplets and their time of arrival can be precisely controlled to within 61 μs in a 500 μm square target region 40 μm wide. The continuous ejection rate of 16 000 droplets per second can be tuned to produce pulsed trains of droplets from 0 up to 357 Hz. The main benefit of this technique is its ease of integration with complex microfluidic processing steps, such as droplet merging, sorting, and encapsulation, prior to sample delivery. With its ability to precisely deliver a small quantity of fluid to a pre-defined location this technology is applicable in X-ray based molecular studies, including the rapidly expanding field of X-ray free electron lasers. Fabrication procedures for this device, the underlying forcing mechanism, the role of nozzle design, and demonstration of the performance in both continuous and on-demand modes are reported.

On-Demand Droplet Merging with an AC Electric Field for Multiple-Volume Droplet Generation

We introduce a unique system to achieve on-demand droplet merging and splitting using a perpendicular AC electric field. The working mechanism involves a micropillar to split droplets, followed by electrocoalescence using an AC electric field. Adjusting the parameters of the AC signal and conductivity of the fluid result in different merging regimes. We observed a minimum threshold voltage and a strong influence of the surfactant. We hypothesize that the merging process is caused by dipole-dipole coalescence between the daughter droplets. At the same time, adjustment of the conductivity reveals a shift in the merging regimes and can be explained with an electric circuit diagram. Size-based sorting using this merging phenomenon is subsequently demonstrated, where alternate, single, double, and triple droplets sorting were achieved. The concept presented in this paper is potentially useful for drug dispensing or multivolume digital polymerase chain reaction, as droplets of multiple sizes can be generated simultaneously.

A Liquid-Metal-Based Dielectrophoretic Microdroplet Generator

This paper proposes a novel microdroplet generator based on the dielectrophoretic (DEP) force. Unlike the conventional continuous microfluidic droplet generator, this droplet generator is more like “invisible electric scissors”. It can cut the droplet off from the fluid matrix and modify droplets’ length precisely by controlling the electrodes’ length and position. These electrodes are made of liquid metal by injection. By applying a certain voltage on the liquid-metal electrodes, the electrodes generate an uneven electric field inside the main microfluidic channel. Then, the uneven electric field generates DEP force inside the fluid. The DEP force shears off part from the main matrix, in order to generate droplets. To reveal the mechanism, numerical simulations were performed to analyze the DEP force. A detailed experimental parametric study was also performed. Unlike the traditional droplet generators, the main separating force of this work is DEP force only, which can produce one droplet at a time in a more precise way.

Microdroplets-on-chip: A review

Single-cell analysis serves as an important approach to study cell functions and interactions. Catering to the demand of Big Data Era, fast reactions for single cells and paralleled high-throughput analysis have become an urgent need. Microdroplet in microfluidics has advantages of modularity and integrity, as well as high throughput and sensitivity, which present great potential in the field of single-cell analysis. This review is carried out on three aspects to introduce microdroplet chips for single-cell analysis: droplet formation, droplet detection and practical functions. Structures of droplet formation are categorized into three types, including T-shaped channel, flow-involved channel and three-dimensional micro-vortice. The detection methods, including fluorescence, Raman spectroscopy, mass spectroscopy and electrochemical detection, are summarized from applications. Both pros and cons for existing techniques are reviewed and discussed. The functions of microdroplets-on-chip cover cell culture, nucleic acid test and cell identification. For each field, principles/mechanisms and/or schematic images are laconically introduced. Microdroplet in microfluidics has become a major research direction in single-cell analysis. With updated methods of droplet formation such as inertial ordering and micro-vortice, microdroplets-based biochips will expect high throughput detection and high-accuracy trace detection for clinical diagnosis in the near future.

Tailoring surface acoustic wave atomisation for cryo-electron microscopy sample preparation

Surface acoustic wave (SAW) atomisation has been widely explored for use in pharmacological delivery, hence performance is characterised predominately in terms of droplet size and maximum delivery of fluid, to ensure sufficient dosage is delivered to the right location. For the application of cryo electron microscopy grid preparation, however, what is required is the transfer of very little fluid onto the grid in a well-defined manner. To meet this requirement, the analysis of SAW atomisation needs to focus on very different characteristics. Specifically, we examine the aerosol jet geometry, in terms of width, cone angle, and elevation angle, and its stability at low power, and hence low flow rates. The variables used are the width and the location of the channel delivering the fluid to the site of atomization. From the experiments, it is observed that we can reach a flowrate as low as 0.55 μl s-1 with reasonable aerosol jet stability, a jet width of 0.5 mm wide and an elevation angle variation as low as 2°.

Microfluidic on-demand droplet generation, storage, retrieval, and merging for single-cell pairing

A multifunctional microfluidic platform combining on-demand aqueous-phase droplet generation, multi-droplet storage, and controlled merging of droplets selected from a storage library in a single integrated microfluidic device is described. A unique aspect of the technology is a microfluidic trap design comprising a droplet trap chamber and lateral bypass channels integrated with a microvalve that supports the capture and merger of multiple droplets over a wide range of individual droplet sizes. A storage unit comprising an array of microfluidic traps operates in a first-in first-out manner, allowing droplets stored within the library to be analyzed before sequentially delivering selected droplets to a downstream merging zone, while shunting other droplets to waste. Performance of the microfluidic trap is investigated for variations in bypass/chamber hydrodynamic resistance ratio, micro-chamber geometry, trapped droplet volume, and overall flow rate. The integrated microfluidic platform is then utilized to demonstrate the operational steps necessary for cell-based assays requiring the isolation of defined cell populations with single cell resolution, including encapsulation of individual cells within an aqueous-phase droplet carrier, screening or incubation of the immobilized cell-encapsulated droplets, and generation of controlled combinations of individual cells through the sequential droplet merging process. Beyond its utility for cell analysis, the presented platform represents a versatile approach to robust droplet generation, storage, and merging for use in a wide range of droplet-based microfluidics applications.

Microfluidics for the Production of Nanomedicines: Considerations for Polymer and Lipid-based Systems

BACKGROUND

Microfluidics is becoming increasingly of interest as a superior technique for the synthesis of nanoparticles, particularly for their use in nanomedicine. In microfluidics, small volumes of liquid reagents are rapidly mixed in a microchannel in a highly controlled manner to form nanoparticles with tunable and reproducible structure that can be tailored for drug delivery. Both polymer and lipid-based nanoparticles are utilized in nanomedicine and both are amenable to preparation by microfluidic approaches.

AIM

Therefore, the purpose of this review is to collect the current state of knowledge on the microfluidic preparation of polymeric and lipid nanoparticles for pharmaceutical applications, including descriptions of the main synthesis modalities. Of special interest are the mechanisms involved in nanoparticle formation and the options for surface functionalisation to enhance cellular interactions.

CONCLUSION

The review will conclude with the identification of key considerations for the production of polymeric and lipid nanoparticles using microfluidic approaches.

Controlling the distance of highly confined droplets in a capillary by interfacial tension for merging on-demand

Droplet microfluidics is a powerful technology that finds many applications in chemistry and biomedicine. Among different configurations, droplets confined in a capillary (or plugs) present a number of advantages: they allow positional identification and simplify the integration of complex multi-steps protocols. However, these protocols rely on the control of droplet speed, which is affected by a complex and still debated interplay of various physico-chemical parameters like droplet length, viscosity ratio between droplets and carrier fluid, flow rate and interfacial tension. We present here a systematic investigation of the droplet speed as a function of their length and interfacial tension, and propose a novel, simple and robust methodology to control the relative distance between consecutive droplets flowing in microfluidic channels through the addition of surfactants either into the dispersed and/or into the continuous phases. As a proof of concept application, we present the possibility to accurately trigger in space and time the merging of two confined droplets flowing in a uniform cross-section circular capillary. This approach is further validated by monitoring a conventional enzymatic reaction used to quantify the concentration of H2O2 in a biological sample, showing its potentialities in both continuous and stopped assay methods.

The size dependant behaviour of particles driven by a travelling surface acoustic wave (TSAW)

The use of travelling surface acoustic waves (TSAW) in a microfluidic system provides a powerful tool for the manipulation of particles and cells. In a TSAW driven system, acoustophoretic effects can cause suspended micro-objects to display three distinct responses: (1) swirling, driven by acoustic streaming forces, (2) migration, driven by acoustic radiation forces and (3) patterning in a spatially periodic manner, resulting from diffraction effects. Whilst the first two phenomena have been widely discussed in the literature, the periodic patterning induced by TSAW has only recently been reported and is yet to be fully elucidated. In particular, more in-depth understanding of the size-dependant nature of this effect and the factors involved are required. Herein, we present an experimental and numerical study of the transition in acoustophoretic behaviour of particles influenced by relative dominance of these three mechanisms and characterise it based on particle diameter, channel height, frequency and intensity of the TSAW driven microfluidic system. This study will enable better understanding of the performance of TSAW sorters and allow the development of TSAW systems for particle collection and patterning.