Numerical Simulation and Experimental Validation of Liquid Metal Droplet Formation in a Co-Flowing Capillary Microfluidic Device

3D printing in microfluidics: experimental optimization of droplet size and generation time through flow focusing, phase, and geometry variation

Droplet-based microfluidics systems have become widely used in recent years thanks to their advantages, varying from the possibility of handling small fluid volumes to directly synthesizing and encapsulating various living forms for biological-related applications. The effectiveness of such systems mainly depends on the ability to control some of these systems' parameters, such as produced droplet size and formation time, which represents a challenging task. This work reports an experimental study on tuning droplet size and generation time in a flow-focusing geometry fabricated with stereolithography 3D printing by exploring the interplay of phase and geometrical parameters. We produced droplets at different low flow rates of continuous and dispersed phases to assess the effect of each of these phases on the droplets' size and formation time. We observed that smaller droplets were produced for high viscosity oil and water phase, along with high flow rates. In addition, changing the microfluidics channels' width, and morphology of the orifice has shown a similar effect on droplet size, as shown in the case of high-viscosity solutions. The variation of the bifurcation angle shows a noticeable variation in terms of the achieved droplet size and formation time. We further investigated the impact of modifying the width ratio of the continuous and dispersed phases on droplet formation.

Numerical Analysis of Droplet Impacting on an Immiscible Liquid via Three-Phase Field Method

In this work, we establish a two-dimensional axisymmetric simulation model to numerically study the impacting behaviors between oil droplets and an immiscible aqueous solution based on the three-phase field method. The numerical model is established by using the commercial software of COMSOL Multiphysics first and then validated by comparing the numerical results with the previous experimental study. The simulation results show that under the impact of oil droplets, a crater will form on the surface of the aqueous solution, which firstly expands and then collapses with the transfer and dissipation of kinetic energy of this three-phase system. As for the droplet, it flattens, spreads, stretches, or immerses on the crater surface and finally achieves an equilibrium state at the gas-liquid interface after experiencing several sinking-bouncing circles. The impacting velocity, fluid density, viscosity, interfacial tension, droplet size, and the property of non-Newtonian fluids all play important roles in the impact between oil droplets and aqueous solution. The conclusions can help to cognize the mechanism of droplet impact on an immiscible fluid and provide useful guidelines for those applications concerning droplet impact.

Microfluidic-assisted fiber production: Potentials, limitations, and prospects

Besides the conventional fiber production methods, microfluidics has emerged as a promising approach for the engineered spinning of fibrous materials and offers excellent potential for fiber manufacturing in a controlled and straightforward manner. This method facilitates low-speed prototype synthesis of fibers for diverse applications while providing superior control over reaction conditions, efficient use of precursor solutions, reagent mixing, and process parameters. This article reviews recent advances in microfluidic technology for the fabrication of fibrous materials with different morphologies and a variety of properties aimed at various applications. First, the basic principles, as well as the latest developments and achievements of microfluidic-based techniques for fiber production, are introduced. Specifically, microfluidic platforms made of glass, polymers, and/or metals, including but not limited to microfluidic chips, capillary-based devices, and three-dimensional printed devices are summarized. Then, fiber production from various materials, such as alginate, gelatin, silk, collagen, and chitosan, using different microfluidic platforms with a broad range of cross-linking agents and mechanisms is described. Therefore, microfluidic spun fibers with diverse diameters ranging from submicrometer scales to hundreds of micrometers and structures, such as cylindrical, hollow, grooved, flat, core-shell, heterogeneous, helical, and peapod-like morphologies, with tunable sizes and mechanical properties are discussed in detail. Subsequently, the practical applications of microfluidic spun fibers are highlighted in sensors for biomedical or optical purposes, scaffolds for culture or encapsulation of cells in tissue engineering, and drug delivery. Finally, different limitations and challenges of the current microfluidic technologies, as well as the future perspectives and concluding remarks, are presented.

A Review of Microfluidic Experimental Designs for Nanoparticle Synthesis

Microfluidics is defined as emerging science and technology based on precisely manipulating fluids through miniaturized devices with micro-scale channels and chambers. Such microfluidic systems can be used for numerous applications, including reactions, separations, or detection of various compounds. Therefore, due to their potential as microreactors, a particular research focus was noted in exploring various microchannel configurations for on-chip chemical syntheses of materials with tailored properties. Given the significant number of studies in the field, this paper aims to review the recently developed microfluidic devices based on their geometry particularities, starting from a brief presentation of nanoparticle synthesis and mixing within microchannels, further moving to a more detailed discussion of different chip configurations with potential use in nanomaterial fabrication.