Analysis of Passive Mixing in a Serpentine Microchannel with Sinusoidal Side Walls

Engineering advancements in microfluidic systems for enhanced mixing at low Reynolds numbers

Mixing within micro- and millichannels is a pivotal element across various applications, ranging from chemical synthesis to biomedical diagnostics and environmental monitoring. The inherent low Reynolds number flow in these channels often results in a parabolic velocity profile, leading to a broad residence time distribution. Achieving efficient mixing at such small scales presents unique challenges and opportunities. This review encompasses various techniques and strategies to evaluate and enhance mixing efficiency in these confined environments. It explores the significance of mixing in micro- and millichannels, highlighting its relevance for enhanced reaction kinetics, homogeneity in mixed fluids, and analytical accuracy. We discuss various mixing methodologies that have been employed to get a narrower residence time distribution. The role of channel geometry, flow conditions, and mixing mechanisms in influencing the mixing performance are also discussed. Various emerging technologies and advancements in microfluidic devices and tools specifically designed to enhance mixing efficiency are highlighted. We emphasize the potential applications of micro- and millichannels in fields of nanoparticle synthesis, which can be utilized for biological applications. Additionally, the prospects of machine learning and artificial intelligence are offered toward incorporating better mixing to achieve precise control over nanoparticle synthesis, ultimately enhancing the potential for applications in these miniature fluidic systems.

An overview on state-of-art of micromixer designs, characteristics and applications

Micromixers are characterized based on characteristics such as excellent mixing efficiency, low reagent cost and flexible controllability compared with conventional reactors in terms of macro size. A variety of designs and applications of micromixers have been proposed. The focus of current reviews is restricted to micromixer structures. Each type of micromixer has characteristics corresponding to its structure, which determines the suitable application areas. This paper provides an overview connecting micromixer designs and their applications. First, the typical designs and mixing mechanisms of both passive and active micromixers are summarized. Then, application cases of micromixers, including chemical, biological and medical applications, are presented. The characteristics, including the advantages and restrictions of different micromixers, are discussed. Finally, the future perspective of micromixer design is proposed. It is predictable that micromixers will have widespread applications by integrating two or more different mixing methods together. This review would be beneficial to guide the design of micromixers applied for specific purposes.

Development of a novel microfluidic perfusion 3D cell culture system for improved neuronal cell differentiation

Three-dimensional (3D) cell cultures have recently gained popularity in the biomedical sciences because of their similarity to the in vivo environment. SH-SY5Y cells, which are neuronal cells and are commonly used to investigate neurodegenerative diseases, have particularly been reported to be differentiated as neuron-like cells expressing neuron-specific markers of mature neurons in static 3D culture environments when compared to static 2D environments, and those in perfusion environments have not yet been investigated. Microfluidic technology has provided perfusion environment which has more similarity to in vivo through mimicking vascular transportation of nutrients, but air bubbles entering into microchannels drastically increase instability of the flow. Furthermore, static incubation commonly used is incompatible with perfusion setup due to its air conditions, which is a critical huddle to the biologists. In the present study, we developed a novel microfluidic perfusion 3D cell culture system that overcomes the disturbance from air bubbles and intuitionally sets the incubation with the perfusion 3D culture. The system is capable of generating concentration gradients between 5 and 95% and air bubble traps were included to increase stability during incubation by collecting air bubbles. To evaluate the perfusion 3D culture, SH-SY5Y differentiation was examined in static 2D, static 3D, and perfusion 3D cultures. Our system supported significantly increased clustering of SH-SY5Y compared to static 2D and 3D methods, as well as increasing neurite growth rate. This novel system therefore supports differentiation of SH-SY5Y and can be used to more accurately model the in vivo environment during cell culture experiments.

Modeling and simulation of a split and recombination-based passive micromixer with vortex-generating mixing units

As a state-of-the-art technology, micromixers are being used in various chemical and biological processes, including polymerization, extraction, crystallization, organic synthesis, biological screening, drug development, drug delivery, etc. The ability of a micromixer to perform efficient mixing while consuming little power is one of its basic needs. In this paper, a passive micromixer having vortex-generating mixing units is proposed which shows effective mixing with a small pressure drop. The micromixer works on the split and recombination (SAR) flow principle. In this study, four micromixers are designed with different arrangements of mixing units, and the effect of the placement of connecting channels is evaluated in terms of mixing index, pressure drop, and mixing performance. The channel width of 200 μm, height of 300 μm, and size of mixing units are maintained constant for all the micromixers throughout the evaluation process. The numerical simulation is performed for the Reynolds number (Re) range of 0.1-100 using Comsol Multiphysics software. By categorizing the flow patterns into three regimes based on the range of Re, the fluid flow throughout the length of the micromixer is visualized. The micromixer with dislocated connecting channels provides a satisfactory result with the mixing index of 0.96 and 0.94, and the pressure drop of 2.5 Pa and 7.8 kPa at Re = 0.1 and Re = 100 respectively. It also outperformed the other models in terms of the mixing performance. The proposed micromixer might very well be used in microfluidic devices for a variety of analytical procedures due to its straightforward construction and outstanding performance.

Microbial stir bars: Light-activated rotation of tethered bacterial cells to enhance mixing in stagnant fluids

Microfluidics devices are gaining significant interest in biomedical applications. However, in a micron-scale device, reaction speed is often limited by the slow rate of diffusion of the reagents. Several active and passive micro-mixers have been fabricated to enhance mixing in microfluidic devices. Here, we demonstrate external control of mixing by rotating a rod-shaped bacterial cell. This rotation is driven by ion transit across the bacterial flagellar stator complex. We first measured the flow fields generated by rotating a single bacterial cell rotationally locked to rotate either clockwise (CW) or counterclockwise (CCW). Micro-particle image velocimetry (μPIV) and particle tracking velocimetry results showed that a bacterial cell of ∼ 2.75 μm long, rotating at 5.75 ± 0.39 Hz in a counterclockwise direction could generate distinct micro-vortices with circular flow fields with a mean velocity of 4.72 ± 1.67 μm/s and maximum velocity of 7.90 μm/s in aqueous solution. We verified our experimental data with a numerical simulation at matched flow conditions, which revealed vortices of similar dimensions and speed. We observed that the flow-field diminished with increasing z-height above the plane of the rotating cell. Lastly, we showed that we could activate and tune rotational mixing remotely using strains engineered with proteorhodopsin, where rotation could be activated by controlled external illumination using green laser light (561 nm).

A Microfluidic System for Investigating Anticipatory Medication Effects on Dopamine Homeostasis in Dopaminergic Cells

Dopamine (DA) homeostasis influences emotions, neural circuit development, cognition, and the reward system. Dysfunctions in DA regulation can lead to neurological disorders, including depression, developmental disorders, and addiction. DA homeostasis disruption is a primary cause of Parkinson's Disease (PD). Therefore, understanding the relationship between DA homeostasis and PD progression may clarify the mechanisms for pharmacologically treating PD. This study developed a novel in vitro DA homeostasis platform which consists of three main parts: (1) a microfluidic device for culturing DAergic neurons, (2) an optical detection system for reading DA levels, and (3) an automatic closed-loop control system that establishes when and how much medication to infuse; this uses a microfluidic device that can cultivate DAergic neurons, perfuse solutions, perform in vitro PD modeling, and continuously monitor DA concentrations. The automatically controlled closed-loop control system simultaneously monitors pharmacological PD treatment to support long-term monitoring of DA homeostasis. SH-SY5Y neuroblastoma cells were chosen as DAergic neurons. They were cultivated in the microfluidic device, and real-time cellular DA level measurements successfully achieved long-term monitoring and modulation of DA homeostasis. When applied in combination with multiday cell culture, this advanced system can be used for drug screening and fundamental biological studies.

Design of a microfluidic mixer channel: First steps into creating a fluorescent dye-based biosensor for mAb aggregate detection

A major challenge in the transition to continuous biomanufacturing is the lack of process analytical technology (PAT) tools which are able to collect real-time information on the process and elicit a response to facilitate control. One of the critical quality attributes (CQAs) of interest during monoclonal antibodies production is aggregate formation. The development of a real-time PAT tool to monitor aggregate formation is then crucial to have immediate feedback and process control. Miniaturized sensors placed after each unit operation can be a powerful solution to speed up an analytical measurement due to their characteristic short reaction time. In this work, a micromixer structure capable of mixing two streams is presented, to be employed in the detection of mAb aggregates using fluorescent dyes. Computational fluid dynamics (CFD) simulations were used to compare the mixing performance of a series of the proposed designs. A final design of a zigzag microchannel with 45° angle was reached and this structure was subsequently fabricated and experimentally validated with colour dyes and, later, with a FITC-IgG molecule. The designed zigzag micromixer presents a mixing index of around 90%, obtained in less than 30 seconds. Therefore, a micromixer channel capable of a fast and efficient mixing is hereby demonstrated, to be used as a real-time PAT tool for a fluorescence based detection of protein aggregation.

Numerical and Experimental Validation of Mixing Efficiency in Periodic Disturbance Mixers

The shape and dimensions of a micromixer are key elements in the mixing process. Accurately quantifying the mixing efficiency enables the evaluation of the performance of a micromixer and the selection of the most suitable one for specific applications. In this paper, two methods are investigated to evaluate the mixing efficiency: a numerical model and an experimental model with a software image processing technique. Using two methods to calculate the mixing efficiency, in addition to corroborating the results and increasing their reliability, creates various possible approaches that can be selected depending on the circumstances, resources, amount of data to be processed and processing time. Image processing is an easy-to-implement tool, is applicable to different programming languages, is flexible, and provides a quick response that allows the calculation of the mixing efficiency using a process of filtering of images and quantifying the intensity of the color, which is associated with the percentage of mixing. The results showed high similarity between the two methods, with a difference ranging between 0 and 6% in all the evaluated points.

Study of the geometry of open channels in a layer-bed-type microfluidic immobilized enzyme reactor

This paper aims at studying open channel geometries in a layer-bed-type immobilized enzyme reactor with computer-aided simulations. The main properties of these reactors are their simple channel pattern, simple immobilization procedure, regenerability, and disposability; all these features make these devices one of the simplest yet efficient enzymatic microreactors. The high surface-to-volume ratio of the reactor was achieved using narrow (25–75 μm wide) channels. The simulation demonstrated that curves support the mixing of solutions in the channel even in strong laminar flow conditions; thus, it is worth including several curves in the channel system. In the three different designs of microreactor proposed, the lengths of the channels were identical, but in two reactors, the liquid flow was split to 8 or 32 parallel streams at the inlet of the reactor. Despite their overall higher volumetric flow rate, the split-flow structures are advantageous due to the increased contact time. Saliva samples were used to test the efficiencies of the digestions in the microreactors.

A cost-effective serpentine micromixer utilizing ellipse curve

Due to high mixing performance and simple geometry structure, serpentine micromixer is one typical passive micromixer that has been widely investigated. Traditional zigzag and square-wave serpentine micromixers can achieve sufficient mixing, but tend to induce significant pressure drop. The excessive pressure drop means more energy consumption, which leads to low cost-performance of mixing. To mitigate excessive pressure drop, a novel serpentine micromixer utilizing ellipse curve is proposed. While fluids flowing through ellipse curve microchannels, the flow directions keep continuous changing. Therefore, the Dean vortices are induced throughout the whole flow path. Numerical simulation and visualization experiments are conducted at Reynolds number (Re) ranging from 0.1 to 100. Dean vortices varies with the changing curvature in different ellipse curves, and local Dean numbers are calculated for quantitative evaluation. The results suggest that the ellipse with a larger eccentricity induces stronger Dean vortices, thus better mixing performance can be obtained. A parameter, named mixing performance cost (Mec), is proposed to evaluate the cost-performance of micromixers. Compared with the zigzag, square-wave and other improved serpentine micromixers, the ellipse curve micromixer produces lower pressure drop while have the capability to maintain excellent mixing performance. The ellipse curve micromixer is proved to be more cost-effective for rapid mixing in complex microfluidic systems.

Surface Response Based Modeling of Liposome Characteristics in a Periodic Disturbance Mixer

Liposomes nanoparticles (LNPs) are vesicles that encapsulate drugs, genes, and imaging labels for advanced delivery applications. Control and tuning liposome physicochemical characteristics such as size, size distribution, and zeta potential are crucial for their functionality. Liposome production using micromixers has shown better control over liposome characteristics compared with classical approaches. In this work, we used our own designed and fabricated Periodic Disturbance Micromixer (PDM). We used Design of Experiments (DoE) and Response Surface Methodology (RSM) to statistically model the relationship between the Total Flow Rate (TFR) and Flow Rate Ratio (FRR) and the resulting liposomes physicochemical characteristics. TFR and FRR effectively control liposome size in the range from 52 nm to 200 nm. In contrast, no significant effect was observed for the TFR on the liposomes Polydispersity Index (PDI); conversely, FRR around 2.6 was found to be a threshold between highly monodisperse and low polydispersed populations. Moreover, it was shown that the zeta potential is independent of TFR and FRR. The developed model presented on the paper enables to pre-establish the experimental conditions under which LNPs would likely be produced within a specified size range. Hence, the model utility was demonstrated by showing that LNPs were produced under such conditions.

Mixing Optimization in Grooved Serpentine Microchannels

Computational fluid dynamics modeling at Reynolds numbers ranging from 10 to 100 was used to characterize the performance of a new type of micromixer employing a serpentine channel with a grooved surface. The new topology exploits the overlap between the typical Dean flows present in curved channels due to the centrifugal forces experienced by the fluids, and the helical flows induced by slanted groove-ridge patterns with respect to the direction of the flow. The resulting flows are complex, with multiple vortices and saddle points, leading to enhanced mixing across the section of the channel. The optimization of the mixers with respect to the inner radius of curvature (R_in) of the serpentine channel identifies the designs in which the mixing index quality is both high (M > 0.95) and independent of the Reynolds number across all the values investigated.

Elaboration of the Demulsification Process of W/O Emulsion with Three-Dimensional Electric Spiral Plate-Type Microchannel

Rapid and efficient demulsification (destabilizing of an emulsion) processes of a water in oil (W/O) emulsion were carried out in a three-dimensional electric spiral plate-type microchannel (3D-ESPM). In this experiment, the demulsifying efficiency of emulsions by 3D-ESPM was compared with that by gravity settling, the factors influencing demulsifying efficiency were investigated, and the induction period, cut size and residence time in the demulsification process were studied. The results showed that in contrast to the gravity settling method, 3D-ESPM can directly separate the disperse phase (water) instead of the continuous phase (oil). The maximum demulsifying efficiency of W/O emulsion in a single pass through the 3D-ESPM reached 90.3%, with a microchannel height of 200 μm, electric field intensity of 250 V /cm, microchannel angle of 180°, microchannel with 18 plates and a flow rate of 2 mL /min. An induction period of 0.6 s during the demulsification process was simulated with experimental data fitting. When the residence time of emulsion in 3D-ESPM was longer than the induction period, its demulsifying efficiency increased as the increase of the flow velocity due to the droplet coalescence effects of Dean vortices in the spiral microchannel. For this device a cut size of droplets of 4.5 μm was deduced. Our results showed that the demulsification process of W/O emulsion was intensified by 3D-ESPM based on the coupling effect between electric field-induced droplets migration and microfluidic hydrodynamic trapping.

Editorial for the Special Issue on Passive Micromixers

Micromixers are important components of microfluidic systems [...].

Performance Analysis and Numerical Evaluation of Mixing in 3-D T-Shape Passive Micromixers

In micromixer devices, laminar characteristics of the flow domain and small diffusion constants of the fluid samples that are mixed characterize the mixing process. The advection dominant flow and transport processes that develop in these devices not only create significant challenges for numerical solution of the problem, but they are also the source of numerical errors which may lead to confusing performance evaluations that are reported in the literature. In this study, the finite volume method (FVM) and finite element method (FEM) are used to characterize these errors and critical issues in numerical performance evaluations are highlighted. In this study, we used numerical methods to evaluate the mixing characteristics of a typical T-shape passive micromixer for several flow and transport parameters using both FEM and FVM, although the numerical procedures described are also equally applicable to other geometric designs as well. The outcome of the study shows that the type of stabilization technique used in FEM is very important and should be documented and reported. Otherwise, erroneous mixing performance may be reported since the added artificial diffusion may significantly affect the mixing performance in the device. Similarly, when FVM methods are used, numerical diffusion errors may become important for certain unstructured discretization techniques that are used in the idealization of the solution domain. This point needs to be also analyzed and reported when FVM is used in performance evaluation of micromixer devices. The focus of this study is not on improving the mixing performance of micromixers. Instead, we highlight the bench scale characteristics of the solutions and the mixing evaluation procedures used when FVM and FEM are employed.

Mixing Performance of a 3D Micro T-Mixer with Swirl-Inducing Inlets and Rectangular Constriction

In this paper, three novel 3D micro T-mixers, namely, a micro T-mixer with swirl-inducing inlets (TMSI), a micro T-mixer with a rectangular constriction (TMRC), and a micro T-mixer with swirl-inducing inlets and a rectangular constriction (TMSC), were proposed on the basis of the original 3D micro T-mixer (OTM). The flow and mixing performance of these micromixers was numerically analyzed using COMSOL Multiphysics package at a range of Reynolds numbers from 10 to 70. Results show that the three proposed 3D micro T-mixers have achieved better mixing performance than OTM. Due to the coupling effect of two swirl-inducing inlets and a rectangular constriction, the maximum mixing index and pressure drop appeared in TMSC among the four micromixers especially; the mixing index of TMSC reaches 91.8% at Re = 70, indicating that TMSC can achieve effective mixing in a short channel length, but has a slightly higher pressure drop than TMSI and TMRC.

Mixing Enhancement in Serpentine Micromixers with a Non-Rectangular Cross-Section

In this numerical study, a new type of serpentine micromixer involving mixing units with a non-rectangular cross-section is investigated. Similar to other serpentine/spiral shaped micromixers, the design exploits the formation of transversal vortices (Dean flows) in pressure-driven systems, associated with the centrifugal forces experienced by the fluid as it is confined to move along curved geometries. In contrast with other previous designs, though, the use of non-rectangular cross-sections that change orientation between mixing units is exploited to control the center of rotation of the transversal flows formed. The associated extensional flows that thus develop between the mixing segments complement the existent rotational flows, leading to a more complex fluid motion. The fluid flow characteristics and associated mixing are determined numerically from computational solutions to Navier⁻Stokes equations and the concentration-diffusion equation. It is found that the performance of the investigated mixers exceeds that of simple serpentine channels with a more consistent behavior at low and high Reynolds numbers. An analysis of the mixing quality using an entropic mixing index indicates that maximum mixing can be achieved at Reynolds numbers as small as 20 in less than four serpentine mixing units.