Microparticle Acoustophoresis in Aluminum-Based Acoustofluidic Devices with PDMS Covers

Assessment of silicon, glass, FR4, PDMS and PMMA as a chip material for acoustic particle/cell manipulation in microfluidics

In the present study, the capabilities of different chip materials for acoustic particle manipulation have been assessed with the same microfluidic device architecture, under the same actuator and flow conditions. Silicon, glass, epoxy with fiberglass filling (FR4), polydimethylsiloxane (PDMS) and polymethyl methacrylate (PMMA) are considered as chip materials. The acoustophoretic chips in this study were manufactured with four different fabrication methods: plasma etching, chemical etching, micromachining and molding. A novel chip material, FR4, has been employed as a microfluidic chip material in acoustophoretic particle manipulation for the first time in literature, which combines the ease of manufacturing of polymer materials with improved acoustic performance. The acoustic particle manipulation performance is evaluated through acoustophoretic focusing experiments with 2μm and 12μm polystyrene microspheres and cultured breast cancer cell line (MDA-MB-231). Unlike the common approach in the literature, the piezoelectric materials were actuated with partitioned cross-polarized electrodes which allowed effective actuation of different family of chip materials. Different from previous studies, this study evaluates the performance of each acoustophoretic device through the perspective of synchronization of electrical, vibrational and acoustical resonances, considers the thermal performance of the chip materials with their effects on cell viability as well as manufacturability and scalability of their fabrication methods. We believe our study is an essential work towards the commercialization of acoustophoretic devices since it brings a critical understanding of the effect of chip material on device performance as well as the cost of achieving that performance.

Transition from Boundary-Driven to Bulk-Driven Acoustic Streaming Due to Nonlinear Thermoviscous Effects at High Acoustic Energy Densities

Acoustic streaming at high acoustic energy densities E_{ac} is studied in a microfluidic channel. It is demonstrated theoretically, numerically, and experimentally with good agreement that frictional heating can alter the streaming pattern qualitatively at high E_{ac} above 400  J/m^{3}. The study shows how as a function of increasing E_{ac} at fixed frequency, the traditional boundary-driven four streaming rolls created at a half-wave standing-wave resonance transition into two large streaming rolls. This nonlinear transition occurs because friction heats up the fluid resulting in a temperature gradient, which spawns an acoustic body force in the bulk that drives thermoacoustic streaming.

On the acoustically induced fluid flow in particle separation systems employing standing surface acoustic waves - Part I

By integrating surface acoustic waves (SAW) into microfluidic devices, microparticle systems can be fractionated precisely in flexible and easily scalable Lab-on-a-Chip platforms. The widely adopted driving mechanism behind this principle is the acoustic radiation force, which depends on the size and acoustic properties of the suspended particles. Superimposed fluid motion caused by the acoustic streaming effect can further manipulate particle trajectories and might have a negative influence on the fractionation result. A characterization of the crucial parameters that affect the pattern and scaling of the acoustically induced flow is thus essential for the design of acoustofluidic separation systems. For the first time, the fluid flow induced by pseudo-standing acoustic wave fields with a wavelength much smaller than the width of the confined microchannel is experimentally revealed in detail, using quantitative three-dimensional measurements of all three velocity components (3D3C). In Part I of this study, we focus on the fluid flow close to the center of the surface acoustic wave field, while in Part II the outer regions with strong acoustic gradients are investigated. By systematic variations of the SAW-wavelength λ_SAW and channel height H, a transition from vortex pairs extending over the entire channel width W to periodic flows resembling the pseudo-standing wave field is revealed. An adaptation of the electrical power, however, only affects the velocity scaling. Based on the experimental data, a validated numerical model was developed in which critical material parameters and boundary conditions were systematically adjusted. Considering a Navier slip length at the substrate-fluid interface, the simulations provide a strong agreement with the measured velocity data over a large frequency range and enable an energetic consideration of the first and second-order fields. Based on the results of this study, critical parameters were identified for the particle size as well as for channel height and width. Progress for the research on SAW-based separation systems is obtained not only by these findings but also by providing all experimental velocity data to allow for further developments on other sites.

Numerical and experimental analysis of a hybrid material acoustophoretic device for manipulation of microparticles

Acoustophoretic microfluidic devices have been developed for accurate, label-free, contactless, and non-invasive manipulation of bioparticles in different biofluids. However, their widespread application is limited due to the need for the use of high quality microchannels made of materials with high specific acoustic impedances relative to the fluid (e.g., silicon or glass with small damping coefficient), manufactured by complex and expensive microfabrication processes. Soft polymers with a lower fabrication cost have been introduced to address the challenges of silicon- or glass-based acoustophoretic microfluidic systems. However, due to their small acoustic impedance, their efficacy for particle manipulation is shown to be limited. Here, we developed a new acoustophoretic microfluid system fabricated by a hybrid sound-hard (aluminum) and sound-soft (polydimethylsiloxane polymer) material. The performance of this hybrid device for manipulation of bead particles and cells was compared to the acoustophoretic devices made of acoustically hard materials. The results show that particles and cells in the hybrid material microchannel travel to a nodal plane with a much smaller energy density than conventional acoustic-hard devices but greater than polymeric microfluidic chips. Against conventional acoustic-hard chips, the nodal line in the hybrid microchannel could be easily tuned to be placed in an off-center position by changing the frequency, effective for particle separation from a host fluid in parallel flow stream models. It is also shown that the hybrid acoustophoretic device deals with smaller temperature rise which is safer for the actuation of bioparticles. This new device eliminates the limitations of each sound-soft and sound-hard materials in terms of cost, adjusting the position of nodal plane, temperature rise, fragility, production cost and disposability, making it desirable for developing the next generation of economically viable acoustophoretic products for ultrasound particle manipulation in bioengineering applications.

Numerical study of bulk acoustofluidic devices driven by thin-film transducers and whole-system resonance modes

In bulk acoustofluidic devices, acoustic resonance modes for fluid and microparticle handling are traditionally excited by bulk piezoelectric (PZE) transducers. In this work, it is demonstrated by numerical simulations in three dimensions that integrated PZE thin-film transducers, constituting less than 0.1% of the bulk device, work equally well. The simulations are performed using a well-tested and experimentally validated numerical model. A water-filled straight channel embedded in a mm-sized bulk glass chip with a 1- μm-thick thin-film transducer made of Al_0.6Sc_0.4N is presented as a proof-of-concept example. The acoustic energy, radiation force, and microparticle focusing times are computed and shown to be comparable to those of a conventional bulk silicon-glass device actuated by a bulk lead-zirconate-titanate transducer. The ability of thin-film transducers to create the desired acoustofluidic effects in bulk acoustofluidic devices relies on three physical aspects: the in-plane-expansion of the thin-film transducer under the applied orthogonal electric field, the acoustic whole-system resonance of the device, and the high Q-factor of the elastic solid, constituting the bulk part of the device. Consequently, the thin-film device is remarkably insensitive to the Q-factor and resonance properties of the thin-film transducer.

Acoustophoresis in polymer-based microfluidic devices: Modeling and experimental validation

A finite-element model is presented for numerical simulation in three dimensions of acoustophoresis of suspended microparticles in a microchannel embedded in a polymer chip and driven by an attached piezoelectric transducer at MHz frequencies. In accordance with the recently introduced principle of whole-system ultrasound resonances, an optimal resonance mode is identified that is related to an acoustic resonance of the combined transducer-chip-channel system and not to the conventional pressure half-wave resonance of the microchannel. The acoustophoretic action in the microchannel is of comparable quality and strength to conventional silicon-glass or pure glass devices. The numerical predictions are validated by acoustic focusing experiments on 5-μm-diameter polystyrene particles suspended inside a microchannel, which was milled into a polymethylmethacrylate chip. The system was driven anti-symmetrically by a piezoelectric transducer, driven by a 30-V peak-to-peak alternating voltage in the range from 0.5 to 2.5 MHz, leading to acoustic energy densities of 13 J/m³ and particle focusing times of 6.6 s.

Theory and simulation of electroosmotic suppression of acoustic streaming

Acoustic handling of nanoparticles in resonating acoustofluidic devices is often impeded by the presence of acoustic streaming. For micrometer-sized acoustic chambers, this acoustic streaming is typically driven by viscous shear in the thin acoustic boundary layer near the fluid-solid interface. Alternating current (ac) electroosmosis is another boundary-driven streaming phenomenon routinely used in microfluidic devices for the handling of particle suspensions in electrolytes. Here, we study how streaming can be suppressed by combining ultrasound acoustics and ac electroosmosis. Based on a theoretical analysis of the electrokinetic problem, we are able to compute numerically a form of the electrical potential at the fluid-solid interface, which is suitable for suppressing the typical acoustic streaming pattern associated with a standing acoustic half-wave. In the linear regime, we even derive an analytical expression for the electroosmotic slip velocity at the fluid-solid interface and use this as a guiding principle for developing models in the experimentally more relevant nonlinear regime that occurs at elevated driving voltages. We present simulation results for an acoustofluidic device, showing how implementing a suitable ac electroosmosis results in a suppression of the resulting electroacoustic streaming in the bulk of the device by 2 orders of magnitude.

A thermoelectrically stabilized aluminium acoustic trap combined with attenuated total reflection infrared spectroscopy for detection of Escherichia coli in water

Acoustic trapping is a non-contact particle manipulation method that holds great potential for performing automated assays. We demonstrate an aluminium acoustic trap in combination with attenuated total reflection Fourier-transform infrared spectroscopy (ATR-FTIR) for detection of E. coli in water. The thermal conductivity of aluminium was exploited to thermo-electrically heat and hold the acoustic trap at the desired assay temperature of 37 °C. Systematic characterisation and optimisation of the acoustic trap allowed high flow rates while maintaining high acoustic trapping performance. The ATR element serves not only as a reflector for ultrasound standing wave generation but also as a sensing interface. The enzyme conversion induced by alkaline phosphatase-labelled bacteria was directly monitored in the acoustic trap using ATR-FTIR spectroscopy. Sequential injection analysis allowed automated liquid handling, including non-contact bacteria retention, washing and enzyme-substrate exchange within the acoustic trap. The presented method was able to detect E. coli concentrations as low as 1.95 × 106 bacteria per mL in 197 min. The demonstrated ultrasound assisted assay paves the way to fully automated bacteria detection devices based on acoustic trapping combined with ATR-FTIR spectroscopy.

Numerical study of the coupling layer between transducer and chip in acoustofluidic devices

By numerical simulation in two and three dimensions, the coupling layer between the transducer and microfluidic chip in ultrasound acoustofluidic devices is studied. The model includes the transducer with electrodes, microfluidic chip with a liquid-filled microchannel, and coupling layer between the transducer and chip. Two commonly used coupling materials, solid epoxy glue and viscous glycerol, as well as two commonly used device types, glass capillary tubes and silicon-glass chips, are considered. It is studied how acoustic resonances in ideal devices without a coupling layer are either sustained or attenuated as a coupling layer of increasing thickness is inserted. A simple criterion based on the phase of the acoustic wave for whether a given zero-layer resonance is sustained or attenuated by the addition of a coupling layer is established. Finally, by controlling the thickness and the material, it is shown that the coupling layer can be used as a design component for optimal and robust acoustofluidic resonances.

Acoustofluidic separation enables early diagnosis of traumatic brain injury based on circulating exosomes

Traumatic brain injury (TBI) is a global cause of morbidity and mortality. Initial management and risk stratification of patients with TBI is made difficult by the relative insensitivity of screening radiographic studies as well as by the absence of a widely available, noninvasive diagnostic biomarker. In particular, a blood-based biomarker assay could provide a quick and minimally invasive process to stratify risk and guide early management strategies in patients with mild TBI (mTBI). Analysis of circulating exosomes allows the potential for rapid and specific identification of tissue injury. By applying acoustofluidic exosome separation-which uses a combination of microfluidics and acoustics to separate bioparticles based on differences in size and acoustic properties-we successfully isolated exosomes from plasma samples obtained from mice after TBI. Acoustofluidic isolation eliminated interference from other blood components, making it possible to detect exosomal biomarkers for TBI via flow cytometry. Flow cytometry analysis indicated that exosomal biomarkers for TBI increase in the first 24 h following head trauma, indicating the potential of using circulating exosomes for the rapid diagnosis of TBI. Elevated levels of TBI biomarkers were only detected in the samples separated via acoustofluidics; no changes were observed in the analysis of the raw plasma sample. This finding demonstrated the necessity of sample purification prior to exosomal biomarker analysis. Since acoustofluidic exosome separation can easily be integrated with downstream analysis methods, it shows great potential for improving early diagnosis and treatment decisions associated with TBI.

Suppression of Acoustic Streaming in Shape-Optimized Channels

Acoustic streaming is an ubiquitous phenomenon resulting from time-averaged nonlinear dynamics in oscillating fluids. In this theoretical study, we show that acoustic streaming can be suppressed by two orders of magnitude in major regions of a fluid by optimizing the shape of its confining walls. Remarkably, the acoustic pressure is not suppressed in this shape-optimized cavity, and neither is the acoustic radiation force on suspended particles. This basic insight may lead to applications, such as acoustophoretic handling of nm-sized particles, which is otherwise impaired by the streaming.