Design and characterization of a 3D-printed staggered herringbone mixer

3D printing holds potential as a faster, cheaper alternative compared with traditional photolithography for the fabrication of microfluidic devices by replica molding. However, the influence of printing resolution and quality on device design and performance has yet to receive detailed study. Here, we investigate the use of 3D-printed molds to create staggered herringbone mixers (SHMs) with feature sizes ranging from ∼100 to 500 μm. We provide guidelines for printer calibration to ensure accurate printing at these length scales and quantify the impacts of print variability on SHM performance. We show that SHMs produced by 3D printing generate well-mixed output streams across devices with variable heights and defects, demonstrating that 3D printing is suitable and advantageous for low-cost, high-throughput SHM manufacturing.

On effects of shape, aspect ratio and position of obstacle on the mixing enhancement in micromixer with hexagonal-shaped chambers

The micromixer geometry presented consists of T-type micromixer with premixing chamber, hexagonal shaped chambers and obstacles. In order to observe influences of obstacle shape, aspect ratio and position, simulations are carried out for two types of obstacle shapes viz. rectangular and triangular for the Reynold number in the range from 0.1 to 75. Flow and mixing dynamics are studied to investigate the effect of geometric modifications for identifying the mixing mechanisms. The effect of obstacle shape, aspect ratio and position is investigated using the performance characteristics viz. mixing index and pressure drop quantitatively. Both the micromixers demonstrate different mixing mechanisms, including transverse flow, vortices and chaotic advection due to split and recombination action. The mixing performance is diffusion dominated below Re < 5 and it is advection dominated beyond Re > 5. At Re ≥ 20, the mixing index observed is 0.80 in all the micromixer design configurations.

Design optimization of micromixer with circular mixing chambers (M-CMC) using Taguchi-based grey relational analysis

The aim of the present study is to optimize the micromixer with circular mixing chambers (M-CMC) using Taguchi-based grey relational analysis approach. Simulations are performed to investigate the effect of design parameters viz. chamber diameter, transverse offset and width of constriction channel on performance characteristics for parameter sets corresponding to Orthogonal Array (OA) L9. Further, grey relational grade is used to identify the optimal set of design parameters. In depth study of flow and mixing dynamics are carried out to visualize the mixing mechanism for optimal and other two cases of proposed micromixer design configuration for Re in the range from 0.1 to 50. In order to assess the response of each design variable at each level, analysis of variance (ANOVA) is also performed to analyse influence of design parameters on mixing index and pressure drop.

Numerical Evaluation of Liquid Mixing in a Serpentine Square Convergent-divergent Passive Micromixer

Micromixers are crucial components to carry out chemical, biomedical and bio-chemical analyses on µTAS (micro total analysis system) or Lab-on-chips. Simple planar type passive mixers are always most desirable over three dimensional or complex geometries of passive mixers or active mixers as they are less expensive, easy to fabricate, and easy to integrate into complex miniaturized systems. However, at very low Reynolds numbers (0 to 100), due to the inherent laminar nature of the microfluidic flows, mixing remains challenging in passive mixers. Previous studies reported that serpentine square-wave micromixer is one of the simple and effective passive device for micromixing. In the present study, to further enhance the mixing efficiency of the device, horizontal straight portions of serpentine square wave mixer are replaced with convergent-divergent passages and the mixing performance of both mixers are evaluated in the Re range of 0 to 100. It is observed in the low Re (0 to 10), mixing in the square wave mixer with convergent-divergent portions (SQW-CD mixer) is governed completely by pure diffusion as in the case of square wave mixer with straight horizontal portions (SQW mixer). However, at high Re (Re > 10), the presence of convergent-divergent portions in the SQW-CD mixer considerably intensify the stretching and folding of samples in the mixing channel. Additionally, the extra recess available at the bends of SQW-CD mixer creates recirculation zones in the mixer. Therefore, a significant improvement in the mixing performance is achieved at high Re (Re > 10) for SQW-CD mixer as compared to conventional SQW mixer. This would allow shorter mixing lengths for SQW-CD mixer as compared to Sq wave mixer. However, with increase in Re, the rise in pressure drop is considerably high for SQW-CD mixer as compared to SQW mixer.

A Micromixer with Two-Layer Crossing Microchannels Based on PMMA Bonding Process

A micromixer with two-layer crossing microchannels based on PMMA bonding process was proposed. The micromixer consists of two-layer crossing microchannels and periodic mixing chambers. The numerical simulation and parameters optimization of the micromixer were carried out in a Reynolds number range of 0.5–100 using CFD software, and the prototype of micromixer was manufactured by PMMA bonding process under certain temperature and pressure condition. The mixing performance of the micromixer was tested and verified by the mixing experiments using red-blue dye. Both the numerical and experimental results confirmed that the micromixer achieves an excellent mixing characteristics over a wide range of Reynolds numbers through generating Dean vortices and chaotic advection. At the same time, the PMMA bonding process proposed in this paper has certain application value and reference significance for expanding the application of three-dimensional flow channels in the field of microfluidics.

Fractal Reactor in Micro-Scale for Process Intensification

Fractal theory, with its novel architectures inspired by nature, provides some novel concepts for smart reactor design. Here, researches on the applications of fractal theory to micro-reactor design are reviewed, in term of its high surface area-to-volume ratio, rapid and direct numbering-up, safety, and precise control. In addition, two designs of fractal micro-reactor are introduced as typical examples. First, the H-type fractal structure is considered in the context of the design of a double-plate micro-reactor, which is used for photocatalytic reactions of CO2. Second, applications of fractal Hilbert curves are considered in the design of channel structures for gas-liquid reactions. These two fractal micro-reactors can be fabricated via 3D printing technology and used for CO2conversion under mild conditions.

Study of Permissible Flow Rate and Mixing Efficiency of the Micromixer Devices

This paper deals with design, simulation, fabrication, analysis of mixing efficiency and thin film bonding stability of the micromixer devices with different flow rates used for lab on chip applications. The objective of the present study is to achieve complete mixing with low flow rate and less pressure drop in low cost polymer microfluidic devices. This paper emphasis the design, simulation and fabrication of straight channel micromixer, serpentine channel micromixer with and without quadrant shaped grooves to study the mixing behavior by the effect of structural dimensions of the microfluidic channel at different flow rates. The designed micromixers were tested with varying rates of flow such as 1, 10, 25, 50, 75 and 100 µL/min.

Numerical Modeling and Parametric Optimization of Micromixer for Low Diffusivity Fluids

This paper deals with the design, analysis and optimization of micro-mixer for fluids having very low diffusivity (in the order of 10−12m2/s) to be used in Lab on Chip (LOC) for medical diagnosis. As flow is laminar and the cross-sectional area is in microscale, the viscous forces are strong causing the fluids to be transported in streamline with minimum diffusion. The main objective in designing a micro mixer is to achieve complete mixing with minimum channel length and pressure drop. In this work a passive micro mixer with two inlets and one outlet (Y shaped passive micro mixer) with obstacles in various shapes and sizes is modelled, to study the effect of mixing. After a CFD analysis, Analysis of variance (ANOVA) of 3Kdesign with 3 parameters as well as a 2Kdesign with 4 parameters was performed to study the effect of parameters on mixing index (mixing length) and pressure loss. There is a negative correlation between the response obtained for mixing length and pressure loss while varying the parameters. This makes it difficult to predict the optimum configuration. Taguchi method is used to obtain an optimum configuration to overcome this negative correlatiozn.

High-Throughput Fabrication of Nanocomplexes Using 3D-Printed Micromixers

3D printing allows a rapid and inexpensive manufacturing of custom made and prototype devices. Micromixers are used for rapid and controlled production of nanoparticles intended for therapeutic delivery. In this study, we demonstrate the fabrication of micromixers using computational design and 3D printing, which enable a continuous and industrial scale production of nanocomplexes formed by electrostatic complexation, using the polymers poly(diallyldimethylammonium chloride) and poly(sodium 4-styrenesulfonate). Several parameters including polymer concentration, flow rate, and flow ratio were systematically varied and their effect on the properties of nanocomplexes was studied and compared with nanocomplexes prepared by bulk mixing. Particles fabricated using this cost effective device were equally small and homogenous but more consistent and controllable in size compared with those prepared manually via bulk mixing. Moreover, each micromixer could process more than 2 liters per hour with unaffected performance and the setup could easily be scaled-up by aligning several micromixers in parallel. This demonstrates that 3D printing can be used to prepare disposable high-throughput micromixers for production of therapeutic nanoparticles.