Toward optimal acoustophoretic microparticle manipulation by exploiting asymmetry

Research advances of acoustic particle manipulation techniques in field-assisted manufacturing

Field-assisted manufacturing (FAM) technology, which employs external fields to transport and manipulate micro/nanoparticles for tailored arrangements and structures, can produce novel materials with specific properties and functions. Acoustic particle manipulation has attracted increasing attention in FAM due to its various advantages, such as a wide range of materials, ease of fabrication, rapid actuation, non-invasive operation and high biocompatibility. The present review summarizes the recent progress of acoustic particle manipulation in the FAM area, with respect to operation principles, fabrication and control of particles, and particle cluster patterning. The emphasis is placed on the recent innovative applications of microparticle manipulation realized by acoustic fields in different advanced manufacturing technologies. Finally, we provide our perspective on the current challenges and potential prospects of acoustic particle manipulation technology in FAM.

Acoustic manipulation of multi-body structures and dynamics

Sound can exert forces on objects of any material and shape. This has made the contactless manipulation of objects by intense ultrasound a fascinating area of research with wide-ranging applications. While much is understood for acoustic forcing of individual objects, sound-mediated interactions among multiple objects at close range gives rise to a rich set of structures and dynamics that are less explored and have been emerging as a frontier for research. We introduce the basic mechanisms giving rise to sound-mediated interactions among rigid as well as deformable particles, focusing on the regime where the particles' size and spacing are much smaller than the sound wavelength. The interplay of secondary acoustic scattering, Bjerknes forces, and micro-streaming is discussed and the role of particle shape is highlighted. Furthermore, we present recent advances in characterizing non-conservative and non-pairwise additive contributions to the particle interactions, along with instabilities and active fluctuations. These excitations emerge at sufficiently strong sound energy density and can act as an effective temperature in otherwise athermal systems.

Acoustophoresis of monodisperse oil droplets in water: Effect of symmetry breaking and non-resonance operation on oil trapping behavior

Acoustic manipulation of particles in microchannels has recently gained much attention. Ultrasonic standing wave (USW) separation of oil droplets or particles is an established technology for microscale applications. Acoustofluidic devices are normally operated at optimized conditions, namely, resonant frequency, to minimize power consumption. It has been recently shown that symmetry breaking is needed to obtain efficient conditions for acoustic particle trapping. In this work, we study the acoustophoretic behavior of monodisperse oil droplets (silicone oil and hexadecane) in water in the microfluidic chip operating at a non-resonant frequency and an off-center placement of the transducer. Finite element-based computer simulations are further performed to investigate the influence of these conditions on the acoustic pressure distribution and oil trapping behavior. Via investigating the Gor'kov potential, we obtained an overlap between the trapping patterns obtained in experiments and simulations. We demonstrate that an off-center placement of the transducer and driving the transducer at a non-resonant frequency can still lead to predictable behavior of particles in acoustofluidics. This is relevant to applications in which the theoretical resonant frequency cannot be achieved, e.g., manipulation of biological matter within living tissues.

Acoustic Trapping: An Emerging Tool for Microfabrication Technology

The high throughput deposition of microscale objects with precise spatial arrangement represents a key step in microfabrication technology. This can be done by creating physical boundaries to guide the deposition process or using printing technologies; in both approaches, these microscale objects cannot be further modified after they are formed. The utilization of dynamic acoustic fields offers a novel approach to facilitate real-time reconfigurable miniaturized systems in a contactless manner, which can potentially be used in physics, chemistry, biology, as well as materials science. Here, the physical interactions of microscale objects in an acoustic pressure field are discussed and how to fabricate different acoustic trapping devices and how to tune the spatial arrangement of the microscale objects are explained. Moreover, different approaches that can dynamically modulate microscale objects in acoustic fields are presented, and the potential applications of the microarrays in biomedical engineering, chemical/biochemical sensing, and materials science are highlighted alongside a discussion of future research challenges.

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.

Theory and modeling of nonperturbative effects in thermoviscous acoustofluidics

A theoretical model of thermal boundary layers and acoustic heating in microscale acoustofluidic devices is presented. Based on it, an iterative numerical model is developed that enables numerical simulation of nonlinear thermoviscous effects due to acoustic heating and thermal advection. Effective boundary conditions are derived and used to enable simulations in three dimensions. The theory shows how friction in the viscous boundary layers causes local heating of the acoustofluidic device. The resulting temperature field spawns thermoacoustic bulk streaming that dominates the traditional boundary-driven Rayleigh streaming at relatively high acoustic energy densities. The model enables simulations of microscale acoustofluidics with high acoustic energy densities and streaming velocities in a range beyond the reach of perturbation theory, and is relevant for design and fabrication of high-throughput acoustofluidic devices.

Acoustic Focusing of Protein Crystals for In-Line Monitoring and Up-Concentration during Serial Crystallography

Serial femtosecond crystallography (SFX) has become one of the standard techniques at X-ray free-electron lasers (XFELs) to obtain high-resolution structural information from microcrystals of proteins. Nevertheless, reliable sample delivery is still often limiting data collection, as microcrystals can clog both field- and flow-focusing nozzles despite in-line filters. In this study, we developed acoustic 2D focusing of protein microcrystals in capillaries that enables real-time online characterization of crystal size and shape in the sample delivery line after the in-line filter. We used a piezoelectric actuator to create a standing wave perpendicular to the crystal flow, which focused lysozyme microcrystals into a single line inside a silica capillary so that they can be imaged using a high-speed camera. We characterized the acoustic contrast factor, focus size, and the coaxial flow lines and developed a splitting union that enables up-concentration to at least a factor of five. The focus size, flow rates, and geometry may enable an upper limit of up-concentration as high as 200 fold. The novel feedback and concentration control could be implemented for serial crystallography at synchrotrons with minor modifications. It will also aid the development of improved sample delivery systems that will increase SFX data collection rates at XFELs, with potential applications to many proteins that can only be purified and crystallized in small amounts.

Acoustophoresis of a resonant elastic microparticle in a viscous fluid medium

This work presents three-dimensional (3D) numerical analysis of acoustic radiation force on an elastic microsphere suspended in a viscous fluid. Acoustophoresis of finite-sized, neutrally buoyant, nearly incompressible soft particles may improve by orders of magnitude and change directions when going through resonant vibrations. These findings offer the potential to manipulate and separate microparticles based on their resonance frequency. This concept has profound implications in cell and microparticle handling, 3D printing, and enrichment in lab-on-chip applications. The existing analytical body of work can predict spheroidal harmonics of an elastic sphere and acoustic radiation force based on monopole and dipole scatter in an ideal fluid. However, little attention is given to the complex interplay of resonant fluid and solid bodies that generate acoustic radiation. The finite element method is used to find resonant modes, damping factors, and acoustic forces of an elastic sphere subject to a standing acoustic wave. Under fundamental spheroidal modes, the radiation force fluctuates significantly around analytical values due to constructive or destructive scatter-incident wave interference. This suggests that for certain materials, relevant to acoustofluidic applications, particle resonances are an important scattering mechanism and design parameter. The 3D model may be applied to any number of particles regardless of geometry or background acoustic field.

Introduction to the special issue on the theory and applications of acoustofluidics

Acoustofluidics is a burgeoning field that applies ultrasound to micro-scale to nano-scale fluidic systems. The discovery of the ability to effectively manipulate fluids and particles at small scales has yielded results that are superior to other approaches and has been built into a diverse range of research. Recasting the fundamentals of acoustics from the past to include new phenomena observed in recent years has allowed acoustical systems to impact new areas, such as drug delivery, diagnostics, and enhanced chemical processes. The contributions in this special issue address a diverse range of research topics in acoustofluidics. Topics include acoustic streaming, flows induced by bubbles, manipulation of particles using acoustic radiation forces, fluid and structural interactions, and contributions suggesting a natural limit to the particle velocity, the ability to deliver molecules to human immune T cells, and microdroplet generation via nozzle-based acoustic atomization.

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.

Recent progress in acoustic field-assisted 3D-printing of functional composite materials

Acoustic forces are an attractive pathway to achieve directed assembly for multi-phase materials via additive processes. Programmatic integration of microstructure and structural features during deposition offers opportunities for optimizing printed component performance. We detail recent efforts to integrate acoustic focusing with a direct-ink-write mode of printing to modulate material transport properties (e.g. conductivity). Acoustic field-assisted printing, operating under a multi-node focusing condition, supports deposition of materials with multiple focused lines in a single-pass printed line. Here, we report the demonstration of acoustic focusing in concert with diffusive self-assembly to rapidly assembly and print multiscale, mm-length colloidal solids on a timescale of seconds to minutes. These efforts support the promising capabilities of acoustic field-assisted deposition-based printing to achieve spatial control of printed microstructures with deterministic, long-range ordering across multiple length scales.

Microfluidics for Multiphase Mixing and Liposomal Encapsulation of Nanobioconjugates: Passive vs. Acoustic Systems

One of the main routes to ensure that biomolecules or bioactive agents remain active as they are incorporated into products with applications in different industries is by their encapsulation. Liposomes are attractive platforms for encapsulation due to their ease of synthesis and manipulation and the potential to fuse with cell membranes when they are intended for drug delivery applications. We propose encapsulating our recently developed cell-penetrating nanobioconjugates based on magnetite interfaced with translocating proteins and peptides with the purpose of potentiating their cell internalization capabilities even further. To prepare the encapsulates (also known as magnetoliposomes (MLPs)), we introduced a low-cost microfluidic device equipped with a serpentine microchannel to favor the interaction between the liposomes and the nanobioconjugates. The encapsulation performance of the device, operated either passively or in the presence of ultrasound, was evaluated both in silico and experimentally. The in silico analysis was implemented through multiphysics simulations with the software COMSOL Multiphysics 5.5® (COMSOL Inc., Stockholm, Sweden) via both a Eulerian model and a transport of diluted species model. The encapsulation efficiency was determined experimentally, aided by spectrofluorimetry. Encapsulation efficiencies obtained experimentally and in silico approached 80% for the highest flow rate ratios (FRRs). Compared with the passive mixer, the in silico results of the device under acoustic waves led to higher discrepancies with respect to those obtained experimentally. This was attributed to the complexity of the process in such a situation. The obtained MLPs demonstrated successful encapsulation of the nanobioconjugates by both methods with a 36% reduction in size for the ones obtained in the presence of ultrasound. These findings suggest that the proposed serpentine micromixers are well suited to produce MLPs very efficiently and with homogeneous key physichochemical properties.

Quantitative assessment of parallel acoustofluidic device

The advantage of ultrasonic fields in harmless and label-free applications intrigued researchers to develop this technology. The capability of acoustofluidic technology for medical applications has not been thoroughly analyzed and visualized. Toward efficient design, in this research, flowing fluid in a microchannel excited by acoustic waves is fully investigated. To study the behavior of acoustic streaming, the main interfering parameters such as inlet velocity, working frequency, displacement amplitude, fluid buffer material, and hybrid effect in a rectangular water-filled microchannel actuated by standing surface acoustic waves are studied. Governing equations for acoustic field and laminar flow are derived employing perturbation theory. For each set of equations, appropriate boundary conditions are applied. Results demonstrate a parallel device is capable of increasing the inlet flow for rapid operations. Frequency increment raises the acoustic streaming velocity magnitude. Displacement amplitude amplification increases the acoustic streaming velocity and helps the streaming flow dominate over the incoming flow. The qualitative analysis of the hybrid effect shows using hard walls can significantly increase the streaming power without depleting excessive energy. A combination of several effective parameters provides an energy-efficient and fully controllable device for biomedical applications such as fluid mixing and cell lysis.

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.

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.