Continuous inertial microparticle and blood cell separation in straight channels with local microstructures

High-efficiency extraction of target particles in viscoelastic contraction-expansion microchannels

The efficient and precise extraction of target particles is a crucial prerequisite for achieving accurate detection and analysis in microfluidic cell analysis. In this study, a symmetrical contraction-expansion microchannel with sheath flow was designed, aiming to extract target larger particles from particles of different sizes within the channel. This paper conducted numerical simulations to investigate the three-dimensional migration mechanisms of particles and performed experimental studies to examine the separation performance of particles with different sizes under varying flow rate ratios and different numbers of contraction-expansion structures. The experimental results indicate that at moderate sample flow rates and higher flow rate ratios, microchannels with fewer contraction-expansion structures are likely to achieve better performance in extracting target particles compared to microchannels with a greater number of these structures. Our work advances the application of viscoelastic contraction-expansion microchannels in particle separation. This device is easy to set up in parallel and significantly enhances throughput, providing an accurate and efficient solution for future particle separation applications.

A High-Throughput Circular Tumor Cell Sorting Chip with Trapezoidal Cross Section

Circulating tumor cells are typically found in the peripheral blood of patients, offering a crucial pathway for the early diagnosis and prediction of cancer. Traditional methods for early cancer diagnosis are inefficient and inaccurate, making it difficult to isolate tumor cells from a large number of cells. In this paper, a new spiral microfluidic chip with asymmetric cross-section is proposed for rapid, high-throughput, label-free enrichment of CTCs in peripheral blood. A mold of the desired flow channel structure was prepared and inverted to make a trapezoidal cross-section using a micro-nanotechnology process of 3D printing. After a systematic study of how flow rate, channel width, and particle concentration affect the performance of the device, we utilized the device to simulate cell sorting of 6 μm, 15 μm, and 25 μm PS (Polystyrene) particles, and the separation efficiency and separation purity of 25 μm PS particles reached 98.3% and 96.4%. On this basis, we realize the enrichment of a large number of CTCs in diluted whole blood (5 mL). The results show that the separation efficiency of A549 was 88.9% and the separation purity was 96.4% at a high throughput of 1400 μL/min. In conclusion, we believe that the developed method is relevant for efficient recovery from whole blood and beneficial for future automated clinical analysis.

Experiment study on focusing pattern prediction of particles in asymmetric contraction-expansion array channel

Contraction-expansion array (CEA) microchannel is a typical structure applied on particle/cell manipulation. The prediction of the particle focusing pattern in CEA microchannel is worthwhile to be investigate deeply. Here, we demonstrated a virtual boundary method by flow field analysis and theoretical derivation. The calculating method of the virtual boundary location, related to the Reynolds number (Re) and the structure parameter RW, was proposed. Combining the approximate Poiseuille flow pattern based on the virtual boundary method with the simulation results of Dean flow, the main line pattern and the main/lateral lines pattern were predicted and validated in experiments. The transformation from the main line pattern to the main/lateral lines pattern can be facilitated by increasing Re, decreasing RW , and decreasing α. An empirical formula was derived to characterize the critical condition of the transformation. The virtual boundary method can provide a guidance for asymmetric CEA channel design and contribute to the widespread application of microfluidic particle focusing.

Micropump integrated white blood cell separation platform for detection of chronic granulomatous disease

White blood cells (WBCs) are robust defenders during antigenic challenges and prime immune cell functioning indicators. High-purity WBC separation is vital for various clinical assays and disease diagnosis. Red blood cells (RBCs) are a major hindrance in WBC separation, constituting 1000 times the WBC population. The study showcases a low-cost micropump integrated microfluidic platform to provide highly purified WBCs for point-of-care testing. An integrated user-friendly microfluidic platform was designed to separate WBCs from finger-prick blood (⁓5 μL), employing an inertial focusing technique. We achieved an efficient WBC separation with 86% WBC purity and 99.99% RBC removal rate in less than 1 min. In addition, the microdevice allows lab-on-chip colorimetric evaluation of chronic granulomatous disease (CGD), a rare genetic disorder affecting globally. The assay duration, straight from separation to disease detection, requires only 20 min. Hence, the proposed microfluidic platform can further be implemented to streamline various clinical procedures involving WBCs in healthcare industries.

Passive microfluidic devices for cell separation

The separation of specific cell populations is instrumental in gaining insights into cellular processes, elucidating disease mechanisms, and advancing applications in tissue engineering, regenerative medicine, diagnostics, and cell therapies. Microfluidic methods for cell separation have propelled the field forward, benefitting from miniaturization, advanced fabrication technologies, a profound understanding of fluid dynamics governing particle separation mechanisms, and a surge in interdisciplinary investigations focused on diverse applications. Cell separation methodologies can be categorized according to their underlying separation mechanisms. Passive microfluidic separation systems rely on channel structures and fluidic rheology, obviating the necessity for external force fields to facilitate label-free cell separation. These passive approaches offer a compelling combination of cost-effectiveness and scalability when compared to active methods that depend on external fields to manipulate cells. This review delves into the extensive utilization of passive microfluidic techniques for cell separation, encompassing various strategies such as filtration, sedimentation, adhesion-based techniques, pinched flow fractionation (PFF), deterministic lateral displacement (DLD), inertial microfluidics, hydrophoresis, viscoelastic microfluidics, and hybrid microfluidics. Besides, the review provides an in-depth discussion concerning cell types, separation markers, and the commercialization of these technologies. Subsequently, it outlines the current challenges faced in the field and presents a forward-looking perspective on potential future developments. This work hopes to aid in facilitating the dissemination of knowledge in cell separation, guiding future research, and informing practical applications across diverse scientific disciplines.

Enhancing particle focusing: a comparative experimental study of modified square wave and square wave microchannels in lift and Dean vortex regimes

Serpentine microchannels are known for their effective particle focusing through Dean flow-induced rotational effects, which are used in compact designs for size-dependent focusing in medical diagnostics. This study explores square serpentine microchannels, a geometry that has recently gained prominence in inertial microfluidics, and presents a modification of square wave microchannels for improved particle separation and focusing. The proposed modification incorporates an additional U-shaped unit to convert the square wave microchannel into a non-axisymmetric structure, which enhances the Dean flow and consequently increases the Dean drag force. Extensive experiments were conducted covering a wide range of Reynolds numbers and particle sizes (2.45 µm to 12 µm). The particle concentration capability and streak position dynamics of the two structures were compared in detail. The results indicate that the modified square-wave microchannel exhibits efficient particle separation in the lower part of the Dean vortex-dominated regime. With increasing Reynolds number, the particles are successively focused into two streaks in the lift force-dominated regime and into a single streak in the Dean vortex-dominated regime, in this modified square wave geometry. These streaks have a low standard deviation around a mean value. In the Dean vortex-dominated regime, the location of the particle stream is highly dependent on the particle size, which allows good particle separation. Particle focusing occurs at lower Reynolds numbers in both the lift-dominated and lift/Dean drag-dominated regions than in the square wave microchannel. The innovative serpentine channel is particularly useful for the Dean drag-dominated regime and introduces a unique asymmetry that affects the particle focusing dynamics. The proposed device offers significant advantages in terms of efficiency, parallelization, footprint, and throughput over existing geometries.

Observations on phenomenological changes in Klebsiella Pneumoniae under fluidic stresses

In the present work, experiments are conducted to understand the consequence of stresses generated by flowing fluid on the bacterial morphology and virulence in microfluidic channels. We consider Klebsiella pneumoniae (KP, a clinical isolate), an ESKAPE pathogen, to be the model bacteria responsible for blood stream infections, bacteremia, including pneumonia, urinary tract infections and more. Four different stress conditions are generated by changing the flow rate and channel geometry subsequently altering the shear rate and stressing time (τ). We observe significant changes in the structural aspects of the stressed bacteria. With an increase in stressing parameters, the viability of the bacterial sample deteriorated. Most importantly, these stressed samples proliferate much more than unstressed samples inside the RAW264.7 murine macrophages. The results shed light on the complex relationship between flow stresses and bacterial virulence. Furthermore, the bacterial samples are challenged with ciprofloxacin to see how they behave under different stress conditions. The observations presented in the present study can be extended to model deadly diseases including bacteremia using organ-on-a-chip technology and to understand bacterial pathogenicity under realistic environments.

Continuous CTC separation through a DEP-based contraction-expansion inertial microfluidic channel

The efficient isolation of viable and intact circulating tumor cells (CTCs) from blood is critical for the genetic analysis of cancer cells, prediction of cancer progression, development of drugs, and evaluation of therapeutic treatments. While conventional cell separation devices utilize the size difference between CTCs and other blood cells, they fail to separate CTCs from white blood cells (WBCs) due to significant size overlap. To overcome this issue, we present a novel approach that combines curved contraction-expansion (CE) channels with dielectrophoresis (DEP) and inertial microfluidics to isolate CTCs from WBCs regardless of size overlap. This label-free and continuous separation method utilizes dielectric properties and size variation of cells for the separation of CTCs from WBCs. The results demonstrate that the proposed hybrid microfluidic channel can effectively isolate A549 CTCs from WBCs regardless of their size with a throughput of 300 μL/min, achieving a high separation distance of 233.4 μm at an applied voltage of 50 Vp-p . The proposed method allows for the modification of cell migration characteristics by controlling the number of CE sections of the channel, applied voltage, applied frequency, and flow rate. With its unique features of a single-stage separation, simple design, and tunability, the proposed method provides a promising alternative to the existing label-free cell separation techniques and may have a wide range of applications in biomedicine.

Biophysical and mechanobiological considerations for T-cell-based immunotherapy

Immunotherapies modulate the body's defense system to treat cancer. While these therapies have shown efficacy against multiple types of cancer, patient response rates are limited, and the off-target effects can be severe. Typical approaches in developing immunotherapies tend to focus on antigen targeting and molecular signaling, while overlooking biophysical and mechanobiological effects. Immune cells and tumor cells are both responsive to biophysical cues, which are prominent in the tumor microenvironment. Recent studies have shown that mechanosensing - including through Piezo1, adhesions, and Yes-associated protein (YAP) and transcriptional coactivator with PDZ-binding motif (TAZ) - influences tumor-immune interactions and immunotherapeutic efficacy. Furthermore, biophysical methods such as fluidic systems and mechanoactivation schemes can improve the controllability and manufacturing of engineered T cells, with potential for increasing therapeutic efficacy and specificity. This review focuses on leveraging advances in immune biophysics and mechanobiology toward improving chimeric antigen receptor (CAR) T-cell and anti-programmed cell death protein 1 (anti-PD-1) therapies.

Collection, nucleic acid release, amplification, and visualization platform for rapid field detection of rice false smut

Rice false smut (RFS) has brought serious food safety problems to the world. Reliable diagnostic tools are needed for the field detection of RFS. Traditional polymerase chain reaction (PCR) is inefficient due to sample transport and preparation, which cannot adapt to the needs of field detection. Herein, we successfully developed a simple, portable microfluidic test platform to rapidly detect RFS. To simplify the operation, we integrated spore purification, nucleic acid release, and amplification into one chip. A micro air pump was used to separate the spores from the impurities and complete the collection of the spores through the airflow. We rapidly lysed spores and released nucleic acids by the benzyl chloride method. The loop-mediated isothermal amplification (LAMP) products could be combined with SYBR Green I to observe the results visually. On-chip sample tests showed that the spore collection efficiency was approximately 78%. By providing on-chip detection results, the chip had 100% specificity and a detection limit of 100 copies/reaction. At the same time, the stability (CV < 5%) and quantitative ability (R² = 0.989) of the chip were also guaranteed. Through the visual detection of large samples, the on-chip detection results were highly concordant with the classical RT-PCR detection results, and the detection timeliness was greatly enhanced. Compared with RT-PCR, the single-sample detection time was shortened by about twenty minutes. The proposed micro-diagnostic tool did not require any large end-point detection instruments and avoided the complicated operation of nucleic acid extraction. As a result, in the future, our microfluidic chip could be used for rapid and real-time monitoring and early warning of rice false smut spores in rice paddies.

Microfluidics for Neuronal Cell and Circuit Engineering

The widespread adoption of microfluidic devices among the neuroscience and neurobiology communities has enabled addressing a broad range of questions at the molecular, cellular, circuit, and system levels. Here, we review biomedical engineering approaches that harness the power of microfluidics for bottom-up generation of neuronal cell types and for the assembly and analysis of neural circuits. Microfluidics-based approaches are instrumental to generate the knowledge necessary for the derivation of diverse neuronal cell types from human pluripotent stem cells, as they enable the isolation and subsequent examination of individual neurons of interest. Moreover, microfluidic devices allow to engineer neural circuits with specific orientations and directionality by providing control over neuronal cell polarity and permitting the isolation of axons in individual microchannels. Similarly, the use of microfluidic chips enables the construction not only of 2D but also of 3D brain, retinal, and peripheral nervous system model circuits. Such brain-on-a-chip and organoid-on-a-chip technologies are promising platforms for studying these organs as they closely recapitulate some aspects of in vivo biological processes. Microfluidic 3D neuronal models, together with 2D in vitro systems, are widely used in many applications ranging from drug development and toxicology studies to neurological disease modeling and personalized medicine. Altogether, microfluidics provide researchers with powerful systems that complement and partially replace animal models.

A high-throughput microfluidic device based on controlled incremental filtration to enable centrifugation-free, low extracorporeal volume leukapheresis

Leukapheresis, the extracorporeal separation of white blood cells (WBCs) from red blood cells (RBCs) and platelets (PLTs), is a life-saving procedure used for treating patients with cancer and other conditions, and as the initial step in the manufacturing of cellular and gene-based therapies. Well-tolerated by adults, leukapheresis poses a significant risk to neonates and low-weight infants because the extracorporeal volume (ECV) of standard centrifugation-based machines represents a particularly large fraction of these patients' total blood volume. Here we describe a novel high-throughput microfluidic device (with a void volume of 0.4 mL) based on controlled incremental filtration (CIF) technology that could replace centrifugation for performing leukapheresis. The CIF device was tested extensively using whole blood from healthy volunteers at multiple hematocrits (5-30%) and flow rates (10-30 mL/min). In the flow-through regime, the CIF device separated WBCs with > 85% efficiency and 10-15% loss of RBCs and PLTs while processing whole blood diluted with saline to 10% hematocrit at a flow rate of 10 mL/min. In the recirculation regime, the CIF device demonstrated a similar level of separation performance, virtually depleting WBCs in the recirculating blood (~ 98% reduction) by the end of a 3.5-hour simulated leukapheresis procedure. Importantly, the device operated without clogging or decline in separation performance, with minimal activation of WBCs and PLTs and no measurable damage to RBCs. Compared to the typical parameters of centrifugation-based leukapheresis, the CIF device had a void volume at least 100-fold smaller, removed WBCs about twice as fast, and lost ~ 2-3-fold fewer PLTs, while operating at a flow rate compatible with the current practice. The hematocrit and flow rate at which the CIF device operated were significantly higher than previously published for other microfluidic cell separation methods. Finally, this study is the first to demonstrate a highly efficient separation of cells from recirculating blood using a microfluidic device. Overall, these findings suggest the feasibility of using high-throughput microfluidic cell separation technology to ultimately enable centrifugation-free, low-ECV leukapheresis. Such a capability would be particularly useful in young children, a vulnerable group of patients who are currently underserved.

Vortex evolution patterns for flow of dilute polymer solutions in confined microfluidic cavities

Flow instability in confined cavities has attracted extensive interest due to its significance in many natural and engineering processes. It also has applications in microfluidic devices for biomedical applications including flow mixing, nanoparticle synthesis, and cell manipulation. The recirculating vortex that characterizes the flow instability is regulated by the fluid rheological properties, cavity geometrical characteristics, and flow conditions, but there is a lack of quantitative understanding of how the vortex evolves as these factors change. Herein, we experimentally study the flow of dilute polymer solutions in confined microfluidic cavities and focus on a quantitative characterization of the vortex evolution. Three typical patterns of vortex evolution are identified in the cavity flow of dilute polymer solutions over a wide range of flow conditions. The geometrical characteristics of the cavity are found to have little effect on the patterns of vortex evolution. The geometry-independent patterns of vortex evolution provide us an intuitive paradigm, from which the interaction and competition among inertial, elastic and shear-thinning effects in these cavity-induced flow instabilities are clarified. These results extend our understanding of the flow instability of complex fluids in confined cavities, and provide useful guidelines for the design of cavity-structured microfluidic devices and their applications.

Scaling microfluidic throughput with flow-balanced manifolds to simply control devices with multiple inlets and outlets

Microfluidics can bring unique functionalities to cell processing, but the small channel dimensions often limit the throughput for cell processing that prevents scaling necessary for key applications. While processing throughput can be improved by increasing cell concentration or flow rate, an excessive number or velocity of cells can result in device failure. Designing parallel channels can linearly increase the throughput by channel number, but for microfluidic devices with multiple inlets and outlets, the design of the channel architecture with parallel channels can result in intractable numbers of inlets and outlets. We demonstrate an approach to use multiple parallel channels for complex microfluidic designs that uses a second manifold layer to connect three inlets and five outlets per channel in a manner that balances flow properties through each channel. The flow balancing in the individual microfluidic channels was accomplished through a combination of analytical and finite element analysis modeling. Volumetric flow and cell flow velocity were measured in each multiplexed channel to validate these models. We demonstrate eight-channel operation of a label-free mechanical separation device that retains the accuracy of a single channel separation. Using the parallelized device and a model biomechanical cell system for sorting of cells based on their viability, we processed over 16 × 10⁶ cells total over three replicates at a rate of 5.3 × 10⁶ cells per hour. Thus, parallelization of complex microfluidics with a flow-balanced manifold system can enable higher throughput processing with the same number of inlet and outlet channels to control.

High-Resolution Separation of Nanoparticles Using a Negative Magnetophoretic Microfluidic System

The separation and purification of a sample of interest is essential for subsequent detection and analysis procedures, but there is a lack of effective separation methods with which to purify nano-sized particles from the sample media. In this paper, a microfluidic system based on negative magnetophoresis is presented for the high-resolution separation of nanoparticles. The system includes on-chip magnetic pole arrays and permalloys that symmetrically distribute on both sides of the separation channel and four permanent magnets that provide strong magnetic fields. The microfluidic system can separate 200 nm particles with a high purity from the mixture (1000 nm and 200 nm particles) due to a magnetic field gradient as high as 10,000 T/m being generated inside the separation channel, which can provide a negative magnetophoretic force of up to 10 pN to the 1000 nm particle. The overall recovery rate of the particles reaches 99%, the recovery rate of 200 nm particles is 84.2%, and the purity reaches 98.2%. Compared with the existing negative magnetophoretic separation methods, our system not only exhibits high resolution on particle sizes (800 nm), but also improves the sample processing throughput, which reaches 2.5 μL/min. The microfluidic system is expected to provide a new solution for the high-purity separation of nanoparticles, as well as nanobiological samples.

High-recovery sorting of cancer cells from whole blood via periodic-focusing inertial microchip

Inertial microfluidic devices continue to show promise for label-free separation of cells from liquid biopsies and other biological samples.

Geometric structure design of passive label-free microfluidic systems for biological micro-object separation

Passive and label-free microfluidic devices have no complex external accessories or detection-interfering label particles. These devices are now widely used in medical and bioresearch applications, including cell focusing and cell separation. Geometric structure plays the most essential role when designing a passive and label-free microfluidic chip. An exquisitely designed geometric structure can change particle trajectories and improve chip performance. However, the geometric design principles of passive and label-free microfluidics have not been comprehensively acknowledged. Here, we review the geometric innovations of several microfluidic schemes, including deterministic lateral displacement (DLD), inertial microfluidics (IMF), and viscoelastic microfluidics (VEM), and summarize the most creative innovations and design principles of passive and label-free microfluidics. We aim to provide a guideline for researchers who have an interest in geometric innovations of passive label-free microfluidics.

A needle tip CCEA microfluidic device based on enhanced Dean flow for cell washing

Particle/cell washing is an essential technique in biological and clinical manipulations. Herein, we propose a novel circular contraction-expansion array (CCEA) microdevice. It can be directly connected to a needle tip without connection tubes. Its small size and centrosymmetric structure are beneficial to low sample consumption, high connection stability, and a wide application range. Computational fluid dynamics (CFD) simulation results show that the CCEA structure can produce a stronger Dean flow and lead to faster particle/cell focusing than the circle structure and CEA structure with the same length. Experimentally, an optimal flow rate ratio of 1:3 and an optimal total flow rate of 120 μL/min were found to ensure a stable fluid distribution. Under these conditions, rapid focusing of 10-20 μm particles with high efficiencies was achieved. Compared with a normal CEA device using tubes, the particle loss rate could be reduced from 64 to 7% when washing 500 μL of a rare sample. Cell suspensions with concentrations from 3 × 105/mL to 1 × 103/mL were tested. The high cell collection efficiency (>85% for three cell lines) and stable waste removal efficiency (>80%) reflected the universality of the CCEA microfluidic device. After the washing, the cell activities of H1299 cells and MCF-7 cells were calculated to be 93.8 and 97.5%, respectively. This needle-tip CCEA microfluidic device showed potential in basic medical research and clinical diagnosis.

Inertial microfluidics: Determining the effect of geometric key parameters on capture efficiency along with a feasibility evaluation for bone marrow cells sorting

Despite great developments in inertial microfluidics, there is still a lack of knowledge to precisely define the particles' behavior in the microchannels. In the present study, as a prerequisite to experimental studies, numerical simulations have been used to study the capture efficiency of target particles in the contraction-expansion microchannel, aiming to provide an estimation of the conditions at which the channel performs best. Fluid analysis based on Navier-Stokes equations is conducted using the finite element method to determine the streamlines and vortices. The highest capture efficiency for 10, 15, and 19-micron particles occurs when the center of the vortex is approximately in the middle of the wide section (at the flow rate of 0.35 ml/min). In addition to investigating the effect of particle diameter and input flow rate, the effect of channel geometry parameters (channel height and initial length of the channel) on particle trapping has also been studied. Also, to consider great interest in separating different-sized bioparticles from a sample, a three-stage platform has been designed to separate four types of bone marrow cells and evaluate the possibility of using contraction-expansion channels in this application.

Label-free inertial-ferrohydrodynamic cell separation with high throughput and resolution

Rapid and label-free separation of target cells from biological samples provided unique opportunity for disease diagnostics and treatment. However, even with advanced technologies for cell separation, the limited throughput, high cost and low separation resolution still prevented their utility in separating cells with well-defined physical features from a large volume of biological samples. Here we described an ultrahigh-throughput microfluidic technology, termed as inertial-ferrohydrodynamic cell separation (inertial-FCS), that rapidly sorted through over 60 milliliters of samples at a throughput of 100 000 cells per second in a label-free manner, differentiating the cells based on their physical diameter difference with ∼1-2 μm separation resolution. Through the integration of inertial focusing and ferrohydrodynamic separation, we demonstrated that the resulting inertial-FCS devices could separate viable and expandable circulating tumor cells from cancer patients' blood with a high recovery rate and high purity. We also showed that the devices could enrich lymphocytes directly from white blood cells based on their physical morphology without any labeling steps. This label-free method could address the needs of high throughput and high resolution cell separation in circulating tumor cell research and adoptive cell transfer immunotherapy.

Inertial microfluidics in contraction-expansion microchannels: A review

Inertial microfluidics has brought enormous changes in the conventional cell/particle detection process and now become the main trend of sample pretreatment with outstanding throughput, low cost, and simple control method. However, inertial microfluidics in a straight microchannel is not enough to provide high efficiency and satisfying performance for cell/particle separation. A contraction-expansion microchannel is a widely used and multifunctional channel pattern involving inertial microfluidics, secondary flow, and the vortex in the chamber. The strengthened inertial microfluidics can help us to focus particles with a shorter channel length and less processing time. Both the vortex in the chamber and the secondary flow in the main channel can trap the target particles or separate particles based on their sizes more precisely. The contraction-expansion microchannels are also capable of combining with a curved, spiral, or serpentine channel to further improve the separation performance. Some recent studies have focused on the viscoelastic fluid that utilizes both elastic forces and inertial forces to separate different size particles precisely with a relatively low flow rate for the vulnerable cells. This article comprehensively reviews various contraction-expansion microchannels with Newtonian and viscoelastic fluids for particle focusing, separation, and microfluid mixing and provides particle manipulation performance data analysis for the contraction-expansion microchannel design.

Secondary-flow-aided single-train elastic-inertial focusing in low elasticity viscoelastic fluids

Elastic-inertial focusing has attracted increasing interest in recent years due to the three-dimensional (3D) single-train focusing ability it offers. However, multi-train focusing, instead of single-train focusing, was observed in viscoelastic fluids with low elasticity as a result of the competition between inertia effect and viscoelasticity effect. To address this issue, we employed the secondary flow to facilitate single-train elastic-inertial focusing in low elasticity viscoelastic fluids. A three-section contraction-expansion channel was designed to induce the secondary flow to pinch the multiplex focusing trains into a single one exactly at the channel centerline. After demonstrating the focusing process and mechanism in our device, we systematically explored and discussed the effects of particle diameter, operational flow rate, polymer concentration, and channel dimension on particle focusing performances. Our device enables single-train focusing of particles in viscoelastic fluids with low elasticity, and offers advantages of planar single-layer structure, and sheathless, external-field free operation.

Inertial focusing of microparticles, bacteria, and blood in serpentine glass channels

Early detection of pathogenic microorganisms is pivotal to diagnosis and prevention of health and safety crises. Standard methods for pathogen detection often rely on lengthy culturing procedures, confirmed by biochemical assays, leading to >24 h for a diagnosis. The main challenge for pathogen detection is their low concentration within complex matrices. Detection of blood-borne pathogens via techniques such as PCR requires an initial positive blood culture and removal of inhibitory blood components, reducing its potential as a diagnostic tool. Among different label-free microfluidic techniques, inertial focusing on microscale channels holds great promise for automation, parallelization, and passive continuous separation of particles and cells. This work presents inertial microfluidic manipulation of small particles and cells (1-10 μm) in curved serpentine glass channels etched at different depths (deep and shallow designs) that can be exploited for (1) bacteria preconcentration from biological samples and (2) bacteria-blood cell separation. In our shallow device, the ability to focus Escherichia coli into the channel side streams with high recovery (89% at 2.2× preconcentration factor) could be applied for bacteria preconcentration in urine for diagnosis of urinary tract infections. Relying on differential equilibrium positions of red blood cells and E. coli inside the deep device, 97% red blood cells were depleted from 1:50 diluted blood with 54% E. coli recovered at a throughput of 0.7 mL/min. Parallelization of such devices could process relevant volumes of 7 mL whole blood in 10 min, allowing faster sample preparation for downstream molecular diagnostics of bacteria present in bloodstream.

A low-cost and high-throughput benchtop cell sorter for isolating white blood cells from whole blood

The ability to isolate and purify white blood cells (WBCs) from mixed ensembles such as blood would benefit autologous cell-based therapeutics as well as diagnosis of WBC disorders. Current WBCs isolation methods have the limitations of low purity or requiring complex and expensive equipment. In addition, due to the overlap in size distribution between lymphocytes (i.e., a sub-population of WBCs) and red blood cells (RBCs), it is challenging to achieve isolation of entire WBCs populations. In this work, we developed an inertial microfluidics-based cell sorter, which enables size-based, high-throughput isolation, and enrichment of WBCs from RBC-lysed whole blood. Using the developed inertial microfluidic chip, the sorting resolution is sharpened within 2 μm, which achieved separation between 3 and 5 μm diameter particles. Thus, with the present cell sorter, a full population of WBCs can be isolated from RBC-lysed blood samples with recovery ratio of 92%, and merely 5% difference in the composition percentage of the three subpopulations of granulocytes, monocytes, and lymphocytes compared to the original sample. Furthermore, our cell sorter is designed to enable broad application of size-based inertial cell sorting by supplying a series of microchips with different sorting cutoff size. This strategy allows us to further enrich the lymphocytes population by twofold using another microchip with a cutoff size between 10 and 15 μm. With simplicity and efficiency, our cell sorter provides a powerful platform for isolating and sorting of WBCs and also envisions broad potential sorting applications for other cell types.

Inertial migration of aerosol particles in three-dimensional microfluidic channels

In recent years, manipulation of particles by inertial microfluidics has attracted significant attention. However, most studies focused on inertial focusing of particles suspended within liquid phase, in which the ratio of the density of the particle to that of the medium is O(1). The investigation on manipulation of aerosol particles in an inertial microfluidics is very limited. In this study, we numerically investigate the aerosol particle's motion in a 3D straight microchannel with rectangular cross section by fully resolved simulation of the particle-air flow. The air flow is modeled by the Navier-Stokes equations. The particle's motions, including translation and rotation, are governed, respectively, by the Newton's second law and the Euler equations without using any approximation models for the lift and drag forces. The coupled mathematical model is numerically solved by combining immersed boundary with lattice Boltzmann method (IB-LBM). We find that the Reynolds number (Re), the particle's initial position, particle's density and diameter are the influential parameters in this process. The equilibrium positions and their stabilities of aerosols are different from those suspended in liquid.

Tunnel dielectrophoresis for ultra-high precision size-based cell separation

In molecular and cellular biological research, cell isolation and sorting are required for accurate investigation of cell populations of specific physical or biological characteristics. By employing unique cell properties to distinguish between heterogeneous cell populations, rapid and accurate sorting with high efficiency is possible. Dielectrophoresis-based cell manipulation has significant promise for separation of cells based on their physical properties and is used in diverse areas ranging from cellular diagnostics to therapeutic applications. In this study, we present a microfluidic device that can achieve label-free and size-based cell separation with high size differential resolution from a mono-cellular population or complex sample matrices. It was realized by using the tunnel dielectrophoresis (TDEP) technique to manipulate the spatial position of individual cells three dimensionally with high resolution. Cells were processed in high speed flows in high ionic strength buffers. A mixture of different sizes of polystyrene micro-particles with a size difference as small as 1 μm can be separated with high purity (>90%). For the first time, high-pass, low-pass, and band-pass filtering within a mono-cellular mammalian cell population were demonstrated with a tunable bandwidth as small as 3 μm. In addition, leukocyte subtype separation was demonstrated by sorting monocytes out of peripheral blood mononuclear cells (PBMCs) from whole blood with high purity (>85%). Its ability to deliver real-time adjustable cut-off threshold size-based cell sorting and its capability to provide an arbitrary cell size pick-up band could potentially enable many research and clinical applications.

Resolving dynamics of inertial migration in straight and curved microchannels by direct cross-sectional imaging

The explosive development of inertial microfluidic systems for label-free sorting and isolation of cells demands improved understanding of the underlying physics that dictate the intriguing phenomenon of size-dependent migration in microchannels. Despite recent advances in the physics underlying inertial migration, migration dynamics in 3D is not fully understood. These investigations are hampered by the lack of easy access to the channel cross section. In this work, we report on a simple method of direct imaging of the channel cross section that is orthogonal to the flow direction using a common inverted microscope, providing vital information on the 3D cross-sectional migration dynamics. We use this approach to revisit particle migration in both straight and curved microchannels. In the rectangular channel, the high-resolution cross-sectional images unambiguously confirm the two-stage migration model proposed earlier. In the curved channel, we found two vertical equilibrium positions and elucidate the size-dependent vertical and horizontal migration dynamics. Based on these results, we propose a critical ratio of blockage ratio (β) to Dean number (De) where no net lateral migration occurs (β/De ∼ 0.01). This dimensionless number (β/De) predicts the direction of lateral migration (inward or outward) in curved and spiral channels, and thus serves as a guideline in design of such channels for particle and cell separation applications. Ultimately, the new approach to direct imaging of the channel cross section enables a wealth of previously unavailable information on the dynamics of inertial migration, which serves to improve our understanding of the underlying physics.

Microfluidic Cell Stretching for Highly Effective Gene Delivery into Hard-to-Transfect Primary Cells

Cell therapy and cellular engineering begin with internalizing synthetic biomolecules and functional nanomaterials into primary cells. Conventionally, electroporation, lipofection, or viral transduction has been used; however, these are limited by their cytotoxicity, low scalability, cost, and/or preparation complexity, especially in primary cells. Thus, a universal intracellular delivery method that outperforms the existing methods must be established. Here, we present a versatile intracellular delivery platform that leverages intrinsic inertial flow developed in a T-junction microchannel with a cavity. The elongational recirculating flows exerted in the channel substantially stretch the cells, creating discontinuities on cell membranes, thereby enabling highly effective internalization of nanomaterials, such as plasmid DNA (7.9 kbp), mRNA, siRNA, quantum dots, and large nanoparticles (300 nm), into different cell types, including hard-to-transfect primary stem and immune cells. We identified that the internalization mechanism of external cargos during the cell elongation-restoration process is achieved by both passive diffusion and convection-based rapid solution exchange across the cell membrane. Using fluidic cell mechanoporation, we demonstrated a transfection yield superior to that of other state-of-the-art microfluidic platforms as well as current benchtop techniques, including lipofectamine and electroporation. In summary, the intracellular delivery platform developed in the present study enables a high delivery efficiency (up to 98%), easy operation (single-step), low material cost (<$1), high scalability (1 × 10⁶ cells/min), minimal cell perturbation (up to 90%), and cell type/cargo insensitive delivery, providing a practical and robust approach anticipated to critically impact cell-based research.

Inertial microfluidics: Recent advances

Inertial microfluidics has attracted significant attentions in last decade due to its superior advantages of high throughput, label- and external field-free operation, simplicity, and low cost. A wide variety of channel geometry designs were demonstrated for focusing, concentrating, isolating, or separating of various bioparticles such as blood components, circulating tumor cells, bacteria, and microalgae. In this review, we first briefly introduce the physics of inertial migration and Dean flow for allowing the readers with diverse backgrounds to have a better understanding of the fundamental mechanisms of inertial microfluidics. Then, we present a comprehensive review of the recent advances and applications of inertial microfluidic devices according to different channel geometries ranging from straight channels, curved channels to contraction-expansion-array channels. Finally, the challenges and future perspective of inertial microfluidics are discussed. Owing to its superior benefit for particle manipulation, the inertial microfluidics will play a more important role in biology and medicine applications.

Channel innovations for inertial microfluidics

Inertial microfluidics has gained significant attention since first being proposed in 2007 owing to the advantages of simplicity, high throughput, precise manipulation, and freedom from an external field. Superior performance in particle focusing, filtering, concentrating, and separating has been demonstrated. As a passive technology, inertial microfluidics technology relies on the unconventional use of fluid inertia in an intermediate Reynolds number range to induce inertial migration and secondary flow, which depend directly on the channel structure, leading to particle migration to the lateral equilibrium position or trapping in a specific cavity. With the advances in micromachining technology, many channel structures have been designed and fabricated in the past decade to explore the fundamentals and applications of inertial microfluidics. However, the channel innovations for inertial microfluidics have not been discussed comprehensively. In this review, the inertial particle manipulations and underlying physics in conventional channels, including straight, spiral, sinusoidal, and expansion-contraction channels, are briefly described. Then, recent innovations in channel structure for inertial microfluidics, especially channel pattern modification and unconventional cross-sectional shape, are reviewed. Finally, the prospects for future channel innovations in inertial microfluidic chips are also discussed. The purpose of this review is to provide guidance for the continued study of innovative channel designs to improve further the accuracy and throughput of inertial microfluidics.

Fully-automated and field-deployable blood leukocyte separation platform using multi-dimensional double spiral (MDDS) inertial microfluidics

A fully-automated and portable leukocyte separation platform was developed based on a new type of inertial microfluidic device, multi-dimensional double spiral (MDDS) device, as an alternative to centrifugation. By combining key innovations in inertial microfluidic device designs and check-valve-based recirculation processes, highly purified and concentrated WBCs (up to >99.99% RBC removal, ∼80% WBC recovery, >85% WBC purity, and ∼12-fold concentrated WBCs compared to the input sample) were achieved in less than 5 minutes, with high reliability and repeatability (coefficient of variation, CV < 5%). Using this, one can harvest up to 0.4 million of intact WBCs from 50 μL of human peripheral blood (50 μL), without any cell damage or phenotypic changes in a fully-automated operation. Alternatively, hand-powered operation is demonstrated with comparable separation efficiency and speed, which eliminates the need for electricity altogether for truly field-friendly sample preparation. The proposed platform is therefore highly deployable for various point-of-care applications, including bedside assessment of the host immune response and blood sample processing in resource-limited environments.

Scaling of deterministic lateral displacement devices to a single column of bumping obstacles

We describe a deterministic lateral displacement (DLD) for particle separation with only a single column of bumping features. The bifurcation of fluid streams at obstacles is not set by the "tilt" of columns with respect to macroscopic current flow, but rather by the fluidic resistances for lateral flow at each obstacle. With one column of 14 bumping features and corresponding inlet/outlet channels, the single-column DLD can separate particles with diameters of 4.8 μm and 9.9 μm at 30 μL min^-1, with an area of only 0.37 mm × 1.5 mm (0.55 mm²). The large-cell output contains over 99% of the 9.9 μm particles and only 0.2% of the 4.8 m particles. The throughput per area of 54 μL min^-1 per mm² represents a 10× increase over previous selective harvesting reports for microfluidic devices in a similar particle size range.

3D particle transport in multichannel microfluidic networks with rough surfaces

The transport of particles and fluids through multichannel microfluidic networks is influenced by details of the channels. Because channels have micro-scale textures and macro-scale geometries, this transport can differ from the case of ideally smooth channels. Surfaces of real channels have irregular boundary conditions to which streamlines adapt and with which particle interact. In low-Reynolds number flows, particles may experience inertial forces that result in trans-streamline movement and the reorganization of particle distributions. Such transport is intrinsically 3D and an accurate measurement must capture movement in all directions. To measure the effects of non-ideal surface textures on particle transport through complex networks, we developed an extended field-of-view 3D macroscope for high-resolution tracking across large volumes ([Formula: see text]) and investigated a model multichannel microfluidic network. A topographical profile of the microfluidic surfaces provided lattice Boltzmann simulations with a detailed feature map to precisely reconstruct the experimental environment. Particle distributions from simulations closely reproduced those observed experimentally and both measurements were sensitive to the effects of surface roughness. Under the conditions studied, inertial focusing organized large particles into an annular distribution that limited their transport throughout the network while small particles were transported uniformly to all regions.

Low-electric-potential-assisted diffusiophoresis for continuous separation of nanoparticles on a chip

Nanoparticle separation techniques are of significant importance in nanoscience and nanotechnological applications and different concentration gradients, electric/dielectric forces, flow/pressure fields, and acoustic waves have been intensively investigated. However, precise separation of nanoparticles has many technical challenges in terms of sizes, shapes, and material properties, limiting the separation resolution, capability, applicability, throughput and so on. In this study, we present a microfluidic device for continuous separation of nanoparticles by combining diffusiophoresis (DP) and electrophoresis (EP) to achieve high separation performance. Concentration gradients formed from sodium chloride (NaCl) and potassium acetate (K-acetate) passively drive the diffusiophoretic migration of nanoparticles. Simultaneously, a low electric potential is additionally applied to impose a synergistic effect on nanoparticle migration by size and surface charge, which is called low-electric-potential-assisted DP (LEPDP). Using a LEPDP-based separation device, we demonstrate the separation of nanoparticles having different sizes (diameters of 500, 200, and 50 nm) and under different surface-charge conditions (carboxylated polystyrene, silica, and polylactide). The resulting separation performance exceeded 95%, in terms of size uniformity, which is about two times better than that obtained using DP alone. We also emphasize that the enhancement of separation performance only needs a small voltage (<1 V), thereby demonstrating that our multiphysical approach could be utilized for high-resolution and portable nanoparticle separation on a chip without the side effects associated with high electric fields. Lastly, we ensure that rapid and precise bio/chemical sensing and analysis of various nanosized particles would be envisioned by strategically combining two nonlinear but synergistic migration effects.

Recent advancements in microfluidics that integrate electrical sensors for whole blood analysis

Whole blood analysis reveals crucial information about various physiological and pathological conditions, including cancer metastasis, infection, and immune status, among others. Despite this rich information, the complex composition of whole blood usually required multiple sample preparation steps to purify targeted analytes. Traditionally, whole blood preparation processes, including centrifugation, lysis, dilution, or staining, are usually manually operated by well-trained technicians using bench-top instruments. This preparation can require a large blood volume and cannot be directly integrated with detection systems. Recently, various studies have integrated microfluidics with electrical sensors for whole blood analysis, with a focus on cell-based analysis, such as cell type, number, morphology, phenotype, and secreted molecules. These miniaturized systems require less sample and shorter reaction times. Besides, the sample processing and analysis can be fully integrated and automated with minimal operations. We believe these systems can transfer the current whole blood analysis from hospitals or laboratories into clinics or home settings to enable real-time and continuous health condition monitoring in point-of-care settings.

Limitation of spiral microchannels for particle separation in heterogeneous mixtures: Impact of particles' size and deformability

Spiral microchannels have shown promising results for separation applications. Hydrodynamic particle-particle interactions are a known factor strongly influencing focusing behaviors in inertial devices, with recent work highlighting how the performance of bidisperse mixtures is altered when compared with pure components in square channels. This phenomenon has not been previously investigated in detail for spiral channels. Here, we demonstrate that, in spiral channels, both the proportion and deformability of larger particles (13 μm diameter) impact upon the recovery (up to 47% decrease) of small rigid particles (4 μm). The effect, observed at low concentrations (volume fraction <0.0012), is attributed to the hydrodynamic capture of beads by larger cells. These changes in particles focusing behavior directly impede the efficiency of the separation-diverting beads from locations expected from measurements with pure populations to co-collection with larger cells-and could hamper deployment of technology for certain applications. Similar focusing behavior alterations were noted when working with purification of stem cell end products.

Lab-on-a-Chip Technologies for the Single Cell Level: Separation, Analysis, and Diagnostics

In the last three decades, microfluidics and its applications have been on an exponential rise, including approaches to isolate rare cells and diagnose diseases on the single-cell level. The techniques mentioned herein have already had significant impacts in our lives, from in-the-field diagnosis of disease and parasitic infections, through home fertility tests, to uncovering the interactions between SARS-CoV-2 and their host cells. This review gives an overview of the field in general and the most notable developments of the last five years, in three parts: 1. What can we detect? 2. Which detection technologies are used in which setting? 3. How do these techniques work? Finally, this review discusses potentials, shortfalls, and an outlook on future developments, especially in respect to the funding landscape and the field-application of these chips.

Computational inertial microfluidics: a review

Since the discovery of inertial focusing in 1961, numerous theories have been put forward to explain the migration of particles in inertial flows, but a complete understanding is still lacking. Recently, computational approaches have been utilized to obtain better insights into the underlying physics. In particular, fundamental aspects of particle focusing inside straight and curved microchannels have been explored in detail to determine the dependence of focusing behavior on particle size, channel shape, and flow Reynolds number. In this review, we differentiate between the models developed for inertial particle motion on the basis of whether they are semi-analytical, Navier-Stokes-based, or built on the lattice Boltzmann method. This review provides a blueprint for the consideration of numerical solutions for modeling of inertial particle motion, whether deformable or rigid, spherical or non-spherical, and whether suspended in Newtonian or non-Newtonian fluids. In each section, we provide the general equations used to solve particle motion, followed by a tutorial appendix and specified sections to engage the reader with details of the numerical studies. Finally, we address the challenges ahead in the modeling of inertial particle microfluidics for future investigators.

Inertial microfluidic cube for automatic and fast extraction of white blood cells from whole blood

We report here a novel inertial microfluidic (IM) cube integrated with lysis, storage and extraction modules for extracting white blood cells (WBCs) from whole blood automatically, harmlessly and quickly. Lysis, storage, and extraction modules are designed to realize the purposes of complete mixing of whole blood and lysing buffer, thorough lysis of red blood cells (RBCs), and automatic extraction of WBCs from the lysed background RBCs, respectively. After demonstrating its conceptual design, we characterize the performances of the lysis and extraction modules. The results show that a high mixing efficiency of 94.2% can be achieved using our lysis modules for complete mixing of whole blood and lysing buffer. In the extraction module, an extraction efficiency of 88.1% can be achieved for the extraction of WBCs. Finally, we successfully apply our IM cube for the high throughput extraction of WBCs from human whole blood with an extraction efficiency of 83.9% and a cell viability of 96.6%, which are comparable to those using centrifugation and even better in some aspects. Our IM cube is based on passive secondary-flow mixing and inertial sorting, offers the advantages of small footprint, high stability and simple fabrication, and is a promising alternative method for extracting WBCs from human blood.

Viscoelastic microfluidics: progress and challenges

The manipulation of cells and particles suspended in viscoelastic fluids in microchannels has drawn increasing attention, in part due to the ability for single-stream three-dimensional focusing in simple channel geometries. Improvement in the understanding of non-Newtonian effects on particle dynamics has led to expanding exploration of focusing and sorting particles and cells using viscoelastic microfluidics. Multiple factors, such as the driving forces arising from fluid elasticity and inertia, the effect of fluid rheology, the physical properties of particles and cells, and channel geometry, actively interact and compete together to govern the intricate migration behavior of particles and cells in microchannels. Here, we review the viscoelastic fluid physics and the hydrodynamic forces in such flows and identify three pairs of competing forces/effects that collectively govern viscoelastic migration. We discuss migration dynamics, focusing positions, numerical simulations, and recent progress in viscoelastic microfluidic applications as well as the remaining challenges. Finally, we hope that an improved understanding of viscoelastic flows in microfluidics can lead to increased sophistication of microfluidic platforms in clinical diagnostics and biomedical research.

Optical fan for single-cell screening

The single-cell screening has attracted great attentions in advanced biomedicine and tissue biology, especially for the early disease diagnosis and treatment monitoring. In this work, by using a specific-designed fiber probe with a flat facet, we propose an "optical fan" strategy to screen K562 cells at the single-cell level from a populations of RBCs. After the 980-nm laser beam injected into the fiber probe, the RBCs were blown away but holding target K562 cells in place. Further, multiple leukemic cells can be screened from hundreds of red blood cells, providing an efficient approach for the cell screening. The experimental results were interpreted by the numerical simulation, and the stiffness of optical fan was also discussed.

Inertial focusing in a parallelogram profiled microchannel over a range of aspect ratios

In this study, particle focusing phenomena are studied in parallelogram and rectangular cross-sectioned microchannels of varying aspect ratio. In contrast to prior work the microchannels were fabricated using anisotropic wet etching of a Si wafer, plasma bonding, and self-alignment between the Si channel and the PDMS mold. It is shown that the inertial focusing points of the fabricated microchannels of parallelogram and rectangular cross-section were modified as the aspect ratio of the microchannels changed. The particle focusing points of the parallelogram profiled microchannel are compared with those of the rectangular microchannel through experimental measurements and CFD simulation. It is shown that particles can be efficiently focused and separated at a relatively low Reynolds number using a parallelogram profiled microchannel with a low aspect ratio.

Tunable microfluidic device fabricated by femtosecond structured light for particle and cell manipulation

Smart devices made of stimuli-responsive (SR) hydrogel can realize accurate shape control with high repeatability attributed to their fast swelling and shrinking upon the change of external stimuli. Integrating these devices into microfluidic chips and utilizing their controllable deformation capability are highly promising approaches to enrich the functions of microfluidic devices and reduce their external apparatuses. Herein we propose and demonstrate a tunable microfluidic device (TMFD) by integrating a pH-sensitive hydrogel microring array into a microchannel. Instantaneous and reversible deformation of the microrings can be finished in less than 200 ms. The array gaps of the microrings are reversibly switched to realize the capture or release of microobjects. In addition, a femtosecond laser holographic processing method is firstly used to pattern and integrate the pH-sensitive hydrogel microrings into a microchannel, and the pH-responsive properties of the hydrogel affected by laser processing dosages are theoretically and experimentally investigated. With this method, the height, diameter (6-16 μm), swelling ratio (35-65%), and diameter change (2-5 μm) can be precisely controlled. As a proof of concept, the filtering of polystyrene particles with multiple sizes and complete trapping of PS particles and cells are demonstrated by these TMFDs. The developed TMFD can be easily integrated by the femtosecond laser holographic processing method, and operates robustly without the need for external precision apparatuses, which hold great promise in the applications of microobject manipulation and biomedical analysis.