Active Femtoliter Droplet Generation in Microfluidics by Confined Interface Vibration

Free-Boundary Microfluidic Platform for Advanced Materials Manufacturing and Applications

Microfluidics, with its remarkable capacity to manipulate fluids and droplets at the microscale, has emerged as a powerful platform in numerous fields. In contrast to conventional closed microchannel microfluidic systems, free-boundary microfluidic manufacturing (FBMM) processes continuous precursor fluids into jets or droplets in a relatively spacious environment. FBMM is highly regarded for its superior flexibility, stability, economy, usability, and versatility in the manufacturing of advanced materials and architectures. In this review, a comprehensive overview of recent advancements in FBMM is provided, encompassing technical principles, advanced material manufacturing, and their applications. FBMM is categorized based on the foundational mechanisms, primarily comprising hydrodynamics, interface effects, acoustics, and electrohydrodynamic. The processes and mechanisms of fluid manipulation are thoroughly discussed. Additionally, the manufacturing of advanced materials in various dimensions ranging from zero-dimensional to three-dimensional, as well as their diverse applications in material science, biomedical engineering, and engineering are presented. Finally, current progress is summarized and future challenges are prospected. Overall, this review highlights the significant potential of FBMM as a powerful tool for advanced materials manufacturing and its wide-ranging applications.

Machine Learning-Aided Microdroplets Breakup Characteristic Prediction in Flow-Focusing Microdevices by Incorporating Variations of Cross-Flow Tilt Angles

Controlling droplet breakup characteristics such as size, frequency, regime, and droplet quality within flow-focusing microfluidic devices is critical for different biomedical applications of droplet microfluidics such as drug delivery, biosensing, and nanomaterial preparation. The development of a prediction platform capable of forecasting droplet breakup characteristics can significantly improve the iterative design and fabrication processes required for achieving desired performance. The present study aims to develop a multipurpose platform capable of predicting the working conditions of user-specific droplet size and frequency and reporting the quality of the generated droplets, regime, and hydrodynamical breakup characteristics in flow-focusing microdevices with different cross-junction tilt angles. Four different neural network-based prediction platforms were compared to accurately estimate capsule size, generation rate, uniformity, and circle metric. The trained capsule size and frequency networks were optimized using the heuristic optimization approach for establishing the Pareto optimal solution plot. To investigate the transition of the droplet generation regime (i.e., squeezing, dripping, and jetting), two different classification models (LDA and MLP) were developed and compared in terms of their prediction accuracy. The MLP model outperformed the LDA model with a cross-validation measure evaluated as 97.85%, demonstrating that the droplet quality and regime prediction models can provide an engineering judgment for the decision maker to choose between the suggested solutions on the Pareto front. The study followed a comprehensive hydrodynamical analysis of the junction angle effect on the dispersed thread formation, pressure, and velocity domains in the orifice.

"Writing biochips": high-resolution droplet-to-droplet manufacturing of analytical platforms

The development of high-resolution molecular printing allows the engineering of analytical platforms enabling applications at the interface between chemistry and biology, i.e. in biosensing, electronics, single-cell biology, and point-of-care diagnostics. Their successful implementation stems from the combination of large area printing at resolutions from sub-100 nm up to macroscale, whilst controlling the composition and volume of the ink, and reconfiguring the deposition features in due course. Similar to handwriting pens, the engineering of continuous writing systems tackles the issue of the tedious ink replenishment between different printing steps. To this aim, this review article provides an unprecedented analysis of the latest continuous printing methods for bioanalytical chemistry, focusing on ink deposition systems based on specific sets of technologies that have been developed to this aim, namely nanofountain probes, microcantilever spotting, capillary-based polymer pens and continuous 3D printing. Each approach will be discussed revealing the most important applications in the fields of biosensors, lab-on-chips and diagnostics.