Highly focused high-frequency travelling surface acoustic waves (SAW) for rapid single-particle sorting

A disposable microfluidic device with a reusable magnetophoretic functional substrate for isolation of circulating tumor cells

We describe an assembly-disposable microfluidic device based on a silicone-coated release polymer thin film. It consists of a disposable polymeric superstrate and a reusable functional substrate and they are assembled simply using vacuum pressure. The disposable polymeric superstrate is manufactured by bonding a silicone-coated release polymer thin film and a microstructured polydimethylsiloxane (PDMS) replica, containing only a simple structured microchannel. The reusable functional substrate generates an intricate energy field that can penetrate the micrometer-thick polymer film into the microchannel and control microfluids. This is the first report to introduce a silicone-coated release polyethylene terephthalate (PET) thin film as a bonding layer on a microstructured PDMS replica. The bonding strength was ∼600 kPa, which is the strongest among bonding methods of PDMS and PET polymer. Additionally, accelerated tests for bond stability and leakage demonstrated that the silicone-coated release PET film can form a very robust bond with PDMS. To demonstrate the usefulness of the proposed assembly-disposable microfluidic device, a lateral magnetophoretic microseparator was developed in an assembly-disposable microfluidic device format and was evaluated for isolating circulating tumor cells (CTCs) from patients with breast cancer.

Acoustic tweezing of particles using decaying opposing travelling surface acoustic waves (DOTSAW)

Surface acoustic waves offer a versatile and biocompatible method of manipulating the location of suspended particles or cells within microfluidic systems. The most common approach uses the interference of identical frequency, counter propagating travelling waves to generate a standing surface acoustic wave, in which particles migrate a distance less than half the acoustic wavelength to their nearest pressure node. The result is the formation of a periodic pattern of particles. Subsequent displacement of this pattern, the prerequisite for tweezing, can be achieved by translation of the standing wave, and with it the pressure nodes; this requires changing either the frequency of the pair of waves, or their relative phase. Here, in contrast, we examine the use of two counterpropagating traveling waves of different frequency. The non-linearity of the acoustic forces used to manipulate particles, means that a small frequency difference between the two waves creates a substantially different force field, which offers significant advantages. Firstly, this approach creates a much longer range force field, in which migration takes place across multiple wavelengths, and causes particles to be gathered together in a single trapping site. Secondly, the location of this single trapping site can be controlled by the relative amplitude of the two waves, requiring simply an attenuation of one of the electrical drive signals. Using this approach, we show that by controlling the powers of the opposing incoherent waves, 5 μm particles can be migrated laterally across a fluid flow to defined locations with an accuracy of ±10 μm.

Droplet trapping and fast acoustic release in a multi-height device with steady-state flow

We demonstrate a novel multilayer polydimethylsiloxane (PDMS) device for selective storage and release of single emulsion droplets. Drops are captured in a microchannel cavity and can be released on-demand through a triggered surface acoustic wave pulse. The surface acoustic wave (SAW) is excited by a tapered interdigital transducer (TIDT) deposited on a piezoelectric lithium niobate (LiNbO₃) substrate and inverts the pressure difference across the cavity trap to push a drop out of the trap and back into the main flow channel. Droplet capture and release does not require a flow rate change, flow interruption, flow inversion or valve action and can be achieved in as fast as 20 ms. This allows both on-demand droplet capture for analysis and monitoring over arbitrary time scales, and continuous device operation with a high droplet rate of 620 drops per s. We hence decouple long-term droplet interrogation from other operations on the chip. This will ease integration with other microfluidic droplet operations and functional components.

Fluorescence activated cell sorting via a focused traveling surface acoustic beam

Fluorescence activated cell sorting (FACS) has become an essential technique widely exploited in biological studies and clinical applications. However, current FACS systems are quite complex, expensive, bulky, and pose potential sample contamination and biosafety issues due to the generation of aerosols in an open environment. Microfluidic technology capable of precise cell manipulation has great potential to reinvent and miniaturize conventional FACS systems. In this work, we demonstrate a benchtop scale FACS system that makes use of a highly focused traveling surface acoustic wave beam to sort out micron-sized particles and biological cells upon fluorescence interrogation at ∼kHz rates. The highly focused acoustic wave beam has a width of ∼50 μm that enables highly accurate sorting of individual particles and cells. We have applied our acoustic FACS system to isolate fluorescently labeled MCF-7 breast cancer cells from diluted whole blood samples with the purity of sorted MCF-7 cells higher than 86%. The cell viability before and after acoustic sorting is higher than 95%, indicating excellent biocompatibility that should enable a variety of cell sorting applications in biomedical research.

Acoustially-mediated microfluidic nanofiltration through graphene films

We exploit the possibility of enhancing the molecular transport of liquids through graphene films using amplitude modulated surface acoustic waves (SAWs) to demonstrate effective and efficient nanoparticle filtration. The use of the SAW, which is an extremely efficient means for driving microfluidic transport, overcomes the need for the large mechanical pumps required to circumvent the large pressure drops encountered in conventional membranes for nanoparticle filtration. 100% filtration efficiency was obtained for micron-dimension particulates, decreasing to only 95% for the filtration of particles of tens of nanometers in dimension, which is comparable to that achieved with other methods. To circumvent clogging of the film, which is typical with all membrane filters, a backwash operation to flush the nanoparticles is incorporated simply by reversing the SAW-induced flow such that 98% recovery of the initial filtration rate is recovered. Given these efficiencies, together with the low cost and compact size of the chipscale SAW devices, we envisage the possibility of scaling out the process by operating a large number of devices in parallel to achieve typical industrial-scale throughputs with potential benefits in terms of substantially lower capital, operating and maintenance costs.

Selective particle and cell capture in a continuous flow using micro-vortex acoustic streaming

Acoustic streaming has emerged as a promising technique for refined microscale manipulation, where strong rotational flow can give rise to particle and cell capture. In contrast to hydrodynamically generated vortices, acoustic streaming is rapidly tunable, highly scalable and requires no external pressure source. Though streaming is typically ignored or minimized in most acoustofluidic systems that utilize other acoustofluidic effects, we maximize the effect of acoustic streaming in a continuous flow using a high-frequency (381 MHz), narrow-beam focused surface acoustic wave. This results in rapid fluid streaming, with velocities orders of magnitude greater than that of the lateral flow, to generate fluid vortices that extend the entire width of a 400 μm wide microfluidic channel. We characterize the forces relevant for vortex formation in a combined streaming/lateral flow system, and use these acoustic streaming vortices to selectively capture 2 μm from a mixed suspension with 1 μm particles and human breast adenocarcinoma cells (MDA-231) from red blood cells.

Huygens-Fresnel Acoustic Interference and the Development of Robust Time-Averaged Patterns from Traveling Surface Acoustic Waves

Periodic pattern generation using time-averaged acoustic forces conventionally requires the intersection of counterpropagating wave fields, where suspended micro-objects in a microfluidic system collect along force potential minimizing nodal or antinodal lines. Whereas this effect typically requires either multiple transducer elements or whole channel resonance, we report the generation of scalable periodic patterning positions without either of these conditions. A single propagating surface acoustic wave interacts with the proximal channel wall to produce a knife-edge effect according to the Huygens-Fresnel principle, where these cylindrically propagating waves interfere with classical wave fronts emanating from the substrate. We simulate these conditions and describe a model that accurately predicts the lateral spacing of these positions in a robust and novel approach to acoustic patterning.

Active droplet sorting in microfluidics: a review

The ability to manipulate and sort droplets is a fundamental issue in droplet-based microfluidics. Various lab-on-a-chip applications can only be realized if droplets are systematically categorized and sorted. These micron-sized droplets act as ideal reactors which compartmentalize different biological and chemical reagents. Array processing of these droplets hinges on the competence of the sorting and integration into the fluidic system. Recent technological advances only allow droplets to be actively sorted at the rate of kilohertz or less. In this review, we present state-of-the-art technologies which are implemented to efficiently sort droplets. We classify the concepts according to the type of energy implemented into the system. We also discuss various key issues and provide insights into various systems.

Acoustic impedance-based manipulation of elastic microspheres using travelling surface acoustic waves

Size-independent separation of particles is performed using difference in acoustic impedances via travelling surface acoustic waves.

Microfluidics cell sample preparation for analysis: Advances in efficient cell enrichment and precise single cell capture

Single cell analysis has received increasing attention recently in both academia and clinics, and there is an urgent need for effective upstream cell sample preparation. Two extremely challenging tasks in cell sample preparation-high-efficiency cell enrichment and precise single cell capture-have now entered into an era full of exciting technological advances, which are mostly enabled by microfluidics. In this review, we summarize the category of technologies that provide new solutions and creative insights into the two tasks of cell manipulation, with a focus on the latest development in the recent five years by highlighting the representative works. By doing so, we aim both to outline the framework and to showcase example applications of each task. In most cases for cell enrichment, we take circulating tumor cells (CTCs) as the target cells because of their research and clinical importance in cancer. For single cell capture, we review related technologies for many kinds of target cells because the technologies are supposed to be more universal to all cells rather than CTCs. Most of the mentioned technologies can be used for both cell enrichment and precise single cell capture. Each technology has its own advantages and specific challenges, which provide opportunities for researchers in their own area. Overall, these technologies have shown great promise and now evolve into real clinical applications.

Continuous micro-vortex-based nanoparticle manipulation via focused surface acoustic waves

Despite increasing demand in the manipulation of nanoscale objects for next generation biological and industrial processes, there is a lack of methods for reliable separation, concentration and purification of nanoscale objects. Acoustic methods have proven their utility in contactless manipulation of microscale objects mainly relying on the acoustic radiation effect, though the influence of acoustic streaming has typically prevented manipulation at smaller length scales. In this work, however, we explicitly take advantage of the strong acoustic streaming in the vicinity of a highly focused, high frequency surface acoustic wave (SAW) beam emanating from a series of focused 6 μm substrate wavelength interdigital transducers patterned on a piezoelectric lithium niobate substrate and actuated with a 633 MHz sinusoidal signal. This streaming field serves to focus fluid streamlines such that incoming particles interact with the acoustic field similarly regardless of their initial starting positions, and results in particle displacements that would not be possible with a travelling acoustic wave force alone. This streaming-induced manipulation of nanoscale particles is maximized with the formation of micro-vortices that extend the width of the microfluidic channel even with the imposition of a lateral flow, occurring when the streaming-induced flow velocities are an order of magnitude larger than the lateral one. We make use of this acoustic streaming to demonstrate the continuous and differential focusing of 100 nm, 300 nm and 500 nm particles.

Advancements in microfluidics for nanoparticle separation

Nanoparticles have been widely implemented for healthcare and nanoscience industrial applications. Thus, efficient and effective nanoparticle separation methods are essential for advancement in these fields. However, current technologies for separation, such as ultracentrifugation, electrophoresis, filtration, chromatography, and selective precipitation, are not continuous and require multiple preparation steps and a minimum sample volume. Microfluidics has offered a relatively simple, low-cost, and continuous particle separation approach, and has been well-established for micron-sized particle sorting. Here, we review the recent advances in nanoparticle separation using microfluidic devices, focusing on its techniques, its advantages over conventional methods, and its potential applications, as well as foreseeable challenges in the separation of synthetic nanoparticles and biological molecules, especially DNA, proteins, viruses, and exosomes.

Virtual membrane for filtration of particles using surface acoustic waves (SAW)

Surface acoustic wave (SAW) based particle manipulation is contactless, versatile, non-invasive and biocompatible making it useful for biological studies and diagnostic technologies. In this work, we present a sensitive particle sorting system, termed the virtual membrane, in which a periodic acoustic field with a wavelength on the order of particle dimensions permits size-selective filtration. Polystyrene particles that are larger than approximately 0.3 times the acoustic half-wavelength experience a force repelling them from the acoustic field. If the particle size is such that, at a given acoustic power and flow velocity, this repulsive force is dominant over the drag force, these particles will be prohibited from progressing further downstream (i.e. filtered), while smaller particles will be able to pass through the force field along the pressure nodes (akin to a filter's pores). Using this mechanism, we demonstrate high size selectivity using a standing SAW generated by opposing sets of focused interdigital transducers (FIDTs). The use of FIDTs permits the generation of a highly localized standing wave field, here used for filtration in μl min(-1) order flow rates at 10s of mW of applied power. Specifically, we demonstrate the filtration of 8 μm particles from 5 μm particles and 10.36 μm particles from 7.0 μm and 5.0 μm particles, using high frequency SAW at 258 MHz, 192.5 MHz, and 129.5 MHz, respectively.

Acoustic tweezers via sub-time-of-flight regime surface acoustic waves

Micrometer-scale acoustic waves are highly useful for refined optomechanical and acoustofluidic manipulation, where these fields are spatially localized along the transducer aperture but not along the acoustic propagation direction. In the case of acoustic tweezers, such a conventional acoustic standing wave results in particle and cell patterning across the entire width of a microfluidic channel, preventing selective trapping. We demonstrate the use of nanosecond-scale pulsed surface acoustic waves (SAWs) with a pulse period that is less than the time of flight between opposing transducers to generate localized time-averaged patterning regions while using conventional electrode structures. These nodal positions can be readily and arbitrarily positioned in two dimensions and within the patterning region itself through the imposition of pulse delays, frequency modulation, and phase shifts. This straightforward concept adds new spatial dimensions to which acoustic fields can be localized in SAW applications in a manner analogous to optical tweezers, including spatially selective acoustic tweezers and optical waveguides.

On-chip droplet production regimes using surface acoustic waves

Aqueous droplets suspended in an immiscible carrier fluid are a key tool in microfluidic chemical analysis platforms. The approaches for producing droplets in microfluidic devices can be divided into three general categories: batch emulsification, continuous production and tailored on-demand production. The major distinctions between each category are the rate of production and the degree of control over the droplet formation process in terms of the size and quantity. On-demand methods are highly desirable when, for example, small numbers or even single droplets of one sample type are required at a time. Here, we present a method for the on-demand production of femtolitre droplets, utilising a pressure source generated by high frequency surface acoustic waves (SAW). An increase in the continuous phase flow rate is enabled by a quasi-3D feature at the droplet production nozzle. A wide range of accessible flow rates permits the identification of different physical regimes in which droplets of different dimensions are produced. In the system investigated droplets measuring as little as 200 fl have been produced, ∼1/60th of the minimum volume previously reported. The experimental findings are supported by a numerical model which demonstrates the link between the number of droplets formed and the pulse length used.

Acoustofluidic particle manipulation inside a sessile droplet: four distinct regimes of particle concentration

In this study, we have investigated the motion of polystyrene microparticles inside a sessile droplet of water actuated by surface acoustic waves (SAWs), which produce an acoustic streaming flow (ASF) and impart an acoustic radiation force (ARF) on the particles. We have categorized four distinct regimes (R1-R4) of particle aggregation that depend on the particle diameter, the SAW frequency, the acoustic wave field (travelling or standing), the acoustic waves' attenuation length, and the droplet volume. The particles are concentrated at the centre of the droplet in the form of a bead (R1), around the periphery of the droplet in the form of a ring (R2), at the side of the droplet in the form of an isolated island (R3), and close to the centre of the droplet in the form of a smaller ring (R4). The ASF-based drag force, the travelling or standing SAW-based ARF, and the centrifugal force are utilized in various combinations to produce these distinct regimes. For simplicity, we fixed the fluid volume at 5 μL, varied the SAW actuation frequency (10, 20, 80, and 133 MHz), and tested several particle diameters in the range 1-30 μm to explicitly demonstrate the regimes R1-R4. We have further demonstrated the separation of particles (1 and 10 μm, 3 and 5 μm) using mixed regime configurations (R1 and R2, R2 and R4, respectively).

Batch process particle separation using surface acoustic waves (SAW): integration of travelling and standing SAW

Acoustic fields are described incorporating travelling and standing wave components to perform size-deterministic particle sorting. This is achieved without the need for fluid flow allowing application to very small volumes in a batch-wise system.