Tuning the Coupled-Domain Response for Efficient Ultrasonic Droplet Generation

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

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

Rapid measurement of the local pressure amplitude in microchannel acoustophoresis using motile cells

Acoustic microfluidics (or acoustofluidics) provides a non-contact and label-free means to manipulate and interrogate bioparticles. Owing to their biocompatibility and precision, acoustofluidic approaches have enabled innovations in various areas of biomedical research. Future breakthroughs will rely on the translation of these techniques from academic labs to clinical and industrial settings. Here, accurate characterization and standardization of device performance are crucial. Versatile, rapid, and widely accessible performance quantification is needed. We propose a field quantification method using motile Chlamydomonas reinhardtii algae cells. We previously reported qualitative mapping of acoustic fields using living microswimmers as active probes. In the present study, we extend our approach to achieve the challenging quantitative in situ measurement of the acoustic energy density. C. reinhardtii cells continuously swim in an imposed force field and dynamically redistribute as the field changes. This behavior allows accurate and complete, real-time performance monitoring, which can be easily applied and adopted within the acoustofluidics and broader microfluidics research communities. Additionally, the approach relies only on standard bright-field microscopy to assess the field under numerous conditions within minutes. We benchmark the method against conventional passive-particle tracking, achieving agreement within 1% for field strengths from 0 to 70 J m^-3 (from 0 to ∼0.8 MPa).

Motile cells as probes for characterizing acoustofluidic devices

Acoustic microfluidics has emerged as a versatile solution for particle manipulation in medicine and biology. However, current technologies are largely confined to specialized research laboratories. The translation of acoustofluidics from research to clinical and industrial settings requires improved consistency and repeatability across different platforms. Performance comparisons will require straightforward experimental assessment tools that are not yet available. We introduce a method for characterizing acoustofluidic devices in real-time by exploiting the capacity of swimming microorganisms to respond to changes in their environment. The unicellular alga, Chlamydomonas reinhardtii, is used as an active probe to visualize the evolving acoustic pressure field within microfluidic channels and chambers. In contrast to more familiar mammalian cells, C. reinhardtii are simple to prepare and maintain, and exhibit a relatively uniform size distribution that more closely resembles calibration particles; however, unlike passive particles, these motile cells naturally fill complex chamber geometries and redistribute when the acoustic field changes or is turned off. In this way, C. reinhardtii cells offer greater flexibility than conventional polymer or glass calibration beads for in situ determination of device operating characteristics. To illustrate the technique, the varying spatial density and distribution of swimming cells are correlated to the acoustic potential to automatically locate device resonances within a specified frequency range. Peaks in the correlation coefficient of successive images not only identify the resonant frequencies for various geometries, but the peak shape can be related to the relative strength of the resonances. Qualitative mapping of the acoustic field strength with increasing voltage amplitude is also shown. Thus, we demonstrate that dynamically responsive C. reinhardtii enable real-time measurement and continuous monitoring of acoustofluidic device performance.

Antibody Conjugate Assembly on Ultrasound-Confined Microcarrier Particles

Bioconjugates are important next-generation drugs and imaging agents. Assembly of these increasingly complex constructs requires precise control over processing conditions, which is a challenge for conventional manual synthesis. This inadequacy has motivated the pursuit of new approaches for efficient, controlled modification of high-molecular-weight biologics such as proteins, carbohydrates, and nucleic acids. We report a novel, hands-free, semiautomated platform for synthetic manipulation of biomolecules using acoustically responsive microparticles as three-dimensional reaction substrates. The microfluidic reactor incorporates a longitudinal acoustic trap that controls the chemical reactions within a localized acoustic field. Forces generated by this field immobilize the microscale substrates against the continuous flow of participating chemical reagents. Thus, the motion of substrates and reactants is decoupled, enabling exquisite control over multistep reaction conditions and providing high-yield, high-purity products with minimal user input. We demonstrate these capabilities by conjugating clinically relevant antibodies with a small molecule. The on-bead synthesis comprises capture of the antibody, coupling of a fluorescent tag, product purification, and product release. Successful capture and modification of a fluorescently labeled antibody are confirmed via fold increases of 49 and 11 in the green (antibody)- and red (small-molecule dye)-channel median intensities determined using flow cytometry. Antibody conjugates assembled on acoustically responsive, ultrasound-confined microparticles exhibit similar quality and quantity to those prepared manually by a skilled technician.

Design, modeling, and experimental validation of an acoustofluidic platform for nanoscale molecular synthesis and detection

Microfluidic technologies are increasingly implemented to replace manual methods in biological and biochemical sample processing. We explore the feasibility of an acoustofluidic trap for confinement of microparticle reaction substrates against continuously flowing reagents in chemical synthesis and detection applications. Computational models are used to predict the flow and ultrasonic standing wave fields within two longitudinal standing bulk acoustic wave (LSBAW) microchannels operated in the 0.5-2.0 MHz range. Glass (gLSBAW) and silicon (siLSBAW) pillar arrays comprise trapping structures that augment the local acoustic field, while openings between pillars evenly distribute the flow for uniform exposure of substrates to reagents. Frequency spectra (acoustic energy density E _ac vs frequency) and model-predicted pressure fields are used to identify longitudinal resonances with pressure minima in bands oriented perpendicular to the inflow direction. Polymeric and glass particles (10- and 20-µm diameter polystyrene beads, 6 µm hollow glass spheres, and 5 µm porous silica microparticles) are confined within acoustic traps operated at longitudinal first and second half-wavelength resonant frequencies (f _1,E = 575 kHz, gLSBAW; f _1,E = 666 kHz; and f _2,E = 1.278 MHz, siLSBAW) as reagents are introduced at 5-10 µl min^-1. Anisotropic silicon etched traps are found to improve augmentation of the acoustic pressure field without reducing the volumetric throughput. Finally, in-channel synthesis of a double-labeled antibody conjugate on ultrasound-confined porous silica microparticles demonstrates the feasibility of the LSBAW platform for synthesis and detection. The results provide a computational and experimental framework for continued advancement of the LSBAW platform for other synthetic processes and molecular detection applications.

Mobile Microfluidics

Microfluidics platforms can program small amounts of fluids to execute a bio-protocol, and thus, can automate the work of a technician and also integrate a large part of laboratory equipment. Although most microfluidic systems have considerably reduced the size of a laboratory, they are still benchtop units, of a size comparable to a desktop computer. In this paper, we argue that achieving true mobility in microfluidics would revolutionize the domain by making laboratory services accessible during traveling or even in daily situations, such as sport and outdoor activities. We review the existing efforts to achieve mobility in microfluidics, and we discuss the conditions mobile biochips need to satisfy. In particular, we show how we adapted an existing biochip for mobile use, and we present the results when using it during a train ride. Based on these results and our systematic discussion, we identify the challenges that need to be overcome at technical, usability and social levels. In analogy to the history of computing, we make some predictions on the future of mobile biochips. In our vision, mobile biochips will disrupt how people interact with a wide range of healthcare processes, including medical testing and synthesis of on-demand medicine.