Droplet Breakup in Expansion-contraction Microchannels

Identification of Evolutionary Trajectories Associated with Antimicrobial Resistance Using Microfluidics

In vitro experimental evolution of pathogens to antibiotics is commonly used for the identification of clinical biomarkers associated with antibiotic resistance. Microdroplet emulsions allow exquisite control of spatial structure, species complexity, and selection microenvironments for such studies. We investigated the use of monodisperse microdroplets in experimental evolution. Using Escherichia coli adaptation to doxycycline, we examined how changes in environmental conditions such as droplet size, starting lambda value, selection strength, and incubation method affected evolutionary outcomes. We also examined the extent to which emulsions could reveal potentially new evolutionary trajectories and dynamics associated with antimicrobial resistance. Interestingly, we identified both expected and unexpected evolutionary trajectories including large-scale chromosomal rearrangements and amplification that were not observed in suspension culture methods. As microdroplet emulsions are well-suited for automation and provide exceptional control of conditions, they can provide a high-throughput approach for biomarker identification as well as preclinical evaluation of lead compounds.

Microfluidics-Enabled Soft Manufacture of Materials with Tailorable Wettability

Microfluidics and wettability are interrelated and mutually reinforcing fields, experiencing synergistic growth. Surface wettability is paramount in regulating microfluidic flows for processing and manipulating fluids at the microscale. Microfluidics, in turn, has emerged as a versatile platform for tailoring the wettability of materials. We present a critical review on the microfluidics-enabled soft manufacture (MESM) of materials with well-controlled wettability and their multidisciplinary applications. Microfluidics provides a variety of liquid templates for engineering materials with exquisite composition and morphology, laying the foundation for precisely controlling the wettability. Depending on the degree of ordering, liquid templates are divided into individual droplets, one-dimensional (1D) arrays, and two-dimensional (2D) or three-dimensional (3D) assemblies for the modular fabrication of microparticles, microfibers, and monolithic porous materials, respectively. Future exploration of MESM will enrich the diversity of chemical composition and physical structure for wettability control and thus markedly broaden the application horizons across engineering, physics, chemistry, biology, and medicine. This review aims to systematize this emerging yet robust technology, with the hope of aiding the realization of its full potential.

Efficient Generation of Microdroplets Using Tail Breakup Induced with Multi-Branch Channels

In recent years, research on the application of microdroplets in the fields of biotechnology and chemistry has made remarkable progress, but the technology for the stable generation of single-micrometer-scale microdroplets has not yet been established. In this paper, we developed an efficient and stable single-micrometer-scale droplet generation device based on the fragmentation of droplet tails, called "tail thread mode", that appears under moderate flow conditions. This method can efficiently encapsulate microbeads that mimic cells and chemical products in passively generated single-micrometer-scale microdroplets. The device has a simple 2D structure; a T-junction is used for droplet generation; and in the downstream, multi-branch channels are designed for droplet deformation into the tail. Several 1-2 µm droplets were successfully produced by the tail's fragmentation; this continuous splitting was induced by the branch channels. We examined a wide range of experimental conditions and found the optimal flow rate condition can be reduced to one-tenth compared to the conventional tip-streaming method. A mold was fabricated by simple soft lithography, and a polydimethylsiloxane (PDMS) device was fabricated using the mold. Based on the 15 patterns of experimental conditions and the results, the key factors for the generation of microdroplets in this device were examined. In the most efficient condition, 61.1% of the total droplets generated were smaller than 2 μm.

Dripping, jetting and tip streaming

Dripping, jetting and tip streaming have been studied up to a certain point separately by both fluid mechanics and microfluidics communities, the former focusing on fundamental aspects while the latter on applications. Here, we intend to review this field from a global perspective by considering and linking the two sides of the problem. First, we present the theoretical model used to study interfacial flows arising in droplet-based microfluidics, paying attention to three elements commonly present in applications: viscoelasticity, electric fields and surfactants. We review both classical and current results of the stability of jets affected by these elements. Mechanisms leading to the breakup of jets to produce drops are reviewed as well, including some recent advances in this field. We also consider the relatively scarce theoretical studies on the emergence and stability of tip streaming in open systems. Second, we focus on axisymmetric microfluidic configurations which can operate on the dripping and jetting modes either in a direct (standard) way or via tip streaming. We present the dimensionless parameters characterizing these configurations, the scaling laws which allow predicting the size of the resulting droplets and bubbles, as well as those delimiting the parameter windows where tip streaming can be found. Special attention is paid to electrospray and flow focusing, two of the techniques more frequently used in continuous drop production microfluidics. We aim to connect experimental observations described in this section of topics with fundamental and general aspects described in the first part of the review. This work closes with some prospects at both fundamental and practical levels.

Microfluidic Encapsulation of Phase-Change Materials for High Thermal Performance

Microencapsulation of phase-change materials (PCMs) can prevent leakage of PCMs and enhance heat transfer with an increased surface area to volume ratio and thus benefit their pragmatic applications. However, the available methods have difficulties in microencapsulating PCMs with a tunable size, structure, and composition at will, thereby failing to accurately and flexibly tailor the thermal properties of microencapsulated PCMs (MEPCMs). Here, the microfluidic encapsulation of PCMs was presented for precisely fabricating MEPCMs with tunable thermal properties. The versatile fabrication of both organic and inorganic MEPCMs was demonstrated with high monodispersity, energy storage capacity, encapsulation efficiency, thermal stability, reliability, and heat charging and discharging rates. Notably, the inorganic MEPCMs exhibit an energy storage capacity of 269.3 J/g and a charging rate of 294.7 J/(g min), surpassing previously reported values. Owing to their high thermal performance, MEPCMs have been used for anticounterfeit applications. Droplet-based microfluidic fabrication opens up a new avenue for versatile fabrication of MEPCMs with well-tailored thermal properties, thus benefitting their applications.

Droplet-based microfluidics systems in biomedical applications

Microfluidics has made a very impressive progress in the past decades due to its unique and instinctive advantages. Droplet-based microfluidic systems show excellent compatibility with many chemical and biological reagents and are capable of performing variety of operations that can implement microreactor, complex multiple core-shell structure, and many applications in biomedical research such as drug encapsulation, targeted drug delivery systems, and multifunctionalization on carriers. Droplet-based systems have been directly used to synthesize particles and encapsulate many biological entities for biomedicine applications due to their powerful encapsulation capability and facile versatility. In this paper, we review its origin, deviation, and evolution to draw a clear future, especially for droplet-based biomedical applications. This paper will focus on droplet generation, variations and complication as starter, and logistically lead to the numerous typical applications in biomedical research. Finally, we will summarize both its challenge and future prospects relevant to its droplet-based biomedical applications.

The role of microfluidics in protein formulations with pre-programmed functional characteristics

Protein-based therapies hold great promise for treating many diseases. Nevertheless, the challenges of producing therapies with targeted attributes via standardized processes may hinder the development of protein formulations and clinical translation of the advanced therapies. Microfluidics represents a promising technology to develop protein formulations with pre-programmed functional characteristics, including size, morphology, and controlled drug release property. In this review, we discuss some examples of adopting microfluidics for fabricating particle- and fiber/tube-based formulations and highlight the advantages of microfluidics-assisted fabrication.

Large-scale water collection of bioinspired cavity-microfibers

Large-scale and high-efficient water collection of microfibers with long-term durability still remains challenging. Here we present well-controlled, bioinspired spindle-knot microfibers with cavity knots (named cavity-microfiber), precisely fabricated via a simple gas-in-water microfluidic method, to address this challenge. The cavity-microfiber is endowed with unique surface roughness, mechanical strength, and long-term durability due to the design of cavity as well as polymer composition, thus enabling an outstanding performance of water collection. The maximum water volume collected on a single knot is almost 495 times than that of the knot on the cavity-microfiber. Moreover, the spider-web-like networks assembled controllably by cavity-microfibers demonstrate excellent large-scale and high-efficient water collection. To maximize the water-collecting capacity, nodes/intersections should be designed on the topology of the network as many as possible. Our light-weighted yet tough, low-cost microfibers with high efficiency in directional water transportation offers promising opportunities for large-scale water collection in water-deficient areas.

Spider-silk-mimicking microfibers often suffer from low efficiency and durability in water collection. Here, the authors fabricate robust microfibers with spindle cavity-knots and different topological fiber-networks with improved water-collecting performance

Microfluidic generation of aqueous two-phase-system (ATPS) droplets by oil-droplet choppers

Existing approaches for droplet generation with an ultra-low interfacial tension using aqueous two-phase systems, ATPS, are either constricted by a narrow range of flow conditions using passive methods or subjected to complex chip fabrication with the integration of external components using active actuation. To address these issues, we present a simple approach to produce uniform ATPS droplets facilitated by oil-droplet choppers in microfluidics. Our solution counts on the synchronized formation of high-interfacial-tension oil-in-water and low-interfacial-tension water-in-water droplets, where the ATPS interface is distorted by oil droplets and decays into water-in-water droplets. In the synchronization regime, the size and generation frequency of ATPS droplets can be controlled independently by tuning the flow rates of the dispersed aqueous and oil phases, respectively. Our method demonstrates high uniformity of droplets (coefficient of variation between 0.75% and 2.45%), a wide range of available droplet size (droplet radius from 5 μm to 180 μm), and a maximum generation frequency of about 2.1 kHz that is nearly two orders of magnitude faster than that in existing methods. We develop theoretical models to precisely predict the minimum and maximum frequencies of droplet generation and the droplet size. The produced ATPS droplets and oil choppers are separated in the channel using density difference. Our method would boost emulsion-based biological applications such as cell encapsulation, biomolecule delivery, bioreactors, and biomaterials synthesis with ATPS droplets.

Well-defined porous membranes for robust omniphobic surfaces via microfluidic emulsion templating

Durability is a long-standing challenge in designing liquid-repellent surfaces. A high-performance omniphobic surface must robustly repel liquids, while maintaining mechanical/chemical stability. However, liquid repellency and mechanical durability are generally mutually exclusive properties for many omniphobic surfaces-improving one performance inevitably results in decreased performance in another. Here we report well-defined porous membranes for durable omniphobic surfaces inspired by the springtail cuticle. The omniphobicity is shown via an amphiphilic material micro-textured with re-entrant surface morphology; the mechanical durability arises from the interconnected microstructures. The innovative fabrication method-termed microfluidic emulsion templating-is facile, cost-effective, scalable and can precisely engineer the structural topographies. The robust omniphobic surface is expected to open up new avenues for diverse applications due to its mechanical and chemical robustness, transparency, reversible Cassie-Wenzel transition, transferability, flexibility and stretchability.

Passive and active droplet generation with microfluidics: a review

Precise and effective control of droplet generation is critical for applications of droplet microfluidics ranging from materials synthesis to lab-on-a-chip systems. Methods for droplet generation can be either passive or active, where the former generates droplets without external actuation, and the latter makes use of additional energy input in promoting interfacial instabilities for droplet generation. A unified physical understanding of both passive and active droplet generation is beneficial for effectively developing new techniques meeting various demands arising from applications. Our review of passive approaches focuses on the characteristics and mechanisms of breakup modes of droplet generation occurring in microfluidic cross-flow, co-flow, flow-focusing, and step emulsification configurations. The review of active approaches covers the state-of-the-art techniques employing either external forces from electrical, magnetic and centrifugal fields or methods of modifying intrinsic properties of flows or fluids such as velocity, viscosity, interfacial tension, channel wettability, and fluid density, with a focus on their implementations and actuation mechanisms. Also included in this review is the contrast among different approaches of either passive or active nature.

Pinch-off of microfluidic droplets with oscillatory velocity of inner phase flow

When one liquid is introduced into another immiscible one, it ultimately fragments due to hydrodynamic instability. In contrast to neck pinch-off without external actuation, the viscous two-fluid system subjected to an oscillatory flow demonstrates higher efficiency in breaking fluid threads. However, the underlying dynamics of this process is less well understood. Here we show that the neck-thinning rate is accelerated by the amplitude of oscillation. By simply evaluating the momentum transfer from external actuation, we derive a dimensionless pre-factor to quantify the accelerated pinch-off. Our data ascribes the acceleration to the non-negligible inner fluid inertia, which neutralizes the inner phase viscous stress that retards the pinch-off. Moreover, we characterize an equivalent neck-thinning behavior between an actuated system and its unactuated counterpart with decreased viscosity ratio. Finally, we demonstrate that oscillation is capable of modulating satellite droplet formation by shifting the pinch-off location. Our study would be useful for manipulating fluids at microscale by external forcing.