Pressure-Free Assembling of Poly(Methyl Methacrylate) Microdevices via Microwave-Assisted Solvent Bonding and Its Biomedical Applications

Poly(methyl methacrylate) (PMMA) has become an appealing material for manufacturing microfluidic chips, particularly for biomedical applications, because of its transparency and biocompatibility, making the development of an appropriate bonding strategy critical. In our research, we used acetic acid as a solvent to create a pressure-free assembly of PMMA microdevices. The acetic acid applied between the PMMA slabs was activated by microwave using a household microwave oven to tightly merge the substrates without external pressure such as clamps. The bonding performance was tested and a superior bond strength of 14.95 ± 0.77 MPa was achieved when 70% acetic acid was used. Over a long period, the assembled PMMA device with microchannels did not show any leakage. PMMA microdevices were also built as a serpentine 2D passive micromixer and cell culture platform to demonstrate their applicability. The results demonstrated that the bonding scheme allows for the easy assembly of PMMAs with a low risk of clogging and is highly biocompatible. This method provides for a simple but robust assembly of PMMA microdevices in a short time without requiring expensive instruments.

Numerical analysis of non-aligned inputs M-type micromixers with different shaped obstacles for biomedical applications

Fluid mixing in lab-on-a-chip devices at laminar flow conditions result in a low mixing index. The reason is dominant diffusion over the convection process. The mixing index can be improved by certain changes in the micromixer structural design like introducing obstacles in the path of fluid flow. These obstacles will make dominant the advection process over the diffusion process. The main contribution of this work is based on proposing the novel hybrid type micromixer design for enhancing the mixing quality. Three non-aligned M-type and non-aligned M-type with obstacles passive type micromixers are analyzed by COMSOL5.5. These designs are hybrid types because different structural changes are combined in a single design for mixing improvement. First of all the straight non-aligned inlets, M-type passive micromixer (SMTM) is analyzed. It is observed that mixing performance is improved because of M-shaped mixing units and non-aligned inlets. This improvement is deemed to be not enough so different shaped obstacles are introduced in the micromixer design. These designs based on obstacles are named horizontal rectangular M-type micromixer, square M-type micromixer, and vertical rectangular M-type micromixer. The mixing index for SMTM, square M-type micromixer, horizontal rectangular M-type micromixer, and vertical rectangular M-type micromixer at Reynolds number Re = 60 is respectively given by 71.1%, 83.21%, 84.45%, and 89.99%. The mixing index of vertical rectangular M-type micromixer was 59.34% − 87.65% for Re = 0.5–100. Vertical rectangular M-type micromixer is concluded with the better-mixing capability design among the proposed ones. Based on these simulation results, the vertical rectangular M-type micromixer design can be utilized for mixing purposes in biomedical applications like nanoparticle synthesis and biomedical sample preparation for drug delivery.

Optimal Combination of Mixing Units Using the Design of Experiments Method

A passive micromixer was designed by combining two mixing units: the cross-channel split and recombined (CC-SAR) and a mixing cell with baffles (MC-B). The passive micromixer was comprised of eight mixing slots that corresponded to four combination units; two mixing slots were grouped as one combination unit. The combination of the two mixing units was based on four combination schemes: (A) first mixing unit, (B) first combination unit, (C) first combination module, and (D) second combination module. The statistical significance of the four combination schemes was analyzed using analysis of variance (ANOVA) in terms of the degree of mixing (DOM) and mixing energy cost (MEC). The DOM and MEC were simulated numerically for three Reynolds numbers (Re = 0.5, 2, and 50), representing three mixing regimes. The combination scheme (B), using different mixing units in the first two mixing slots, was significant for Re = 2 and 50. The four combination schemes had little effect on the mixing performance of a passive micromixer operating in the mixing regime of molecular dominance. The combination scheme (B) was generalized to arbitrary mixing slots, and its significance was analyzed for Re = 2 and 50. The general combination scheme meant two different mixing units in two consecutive mixing slots. The numerical simulation results showed that the general combination scheme was statistically significant in the first three combination units for Re = 2, and significant in the first two combination units for Re = 50. The combined micromixer based on the general combination scheme throughout the entire micromixer showed the best mixing performance over a wide range of Reynolds numbers, compared to other micromixers that did not adopt completely the general combination scheme. The most significant enhancement due to the general combination scheme was observed in the transition mixing scheme and was negligible in the molecular dominance scheme. The combination order was less significant after three combination units.

Simple, Cost-Effective Fabrication, and Flow Dynamics Analysis of a Passive Microfluidic Mixer Using 3D Printing and Soft Lithography

Simple and low-cost fabrication of microfluidic devices has attracted considerable attention among researchers. The traditional soft lithography fabrication method requires expensive equipment like a UV exposure system and mask fabrication facility. In this work, an alternative and low-cost UV exposure system was introduced along with an alternative mask fabrication system. A previously reported passive microfluidic mixer was fabricated successfully using this modified soft lithography method. Challenges were presented during this modified fabrication method. Another emerging potential alternative for the fabrication of microfluidic mixers is 3D printing. It was also used in this experiment to fabricate a passive micromixer. This method is well known for rapid prototyping and the creations of complex structures. However, this method has several disadvantages like optical transparency, lower resolution fabrication, difficulties in flow characterization, etc. These problems were addressed, and the solutions were discussed in this work. Comparative analysis between 3D printing and soft lithography fabrication was presented. Flow characterization inside the 3D printed micromixer was carried out using the microparticulate image velocimetry (micro-PIV) system. It explains how the geometrical shape of the micromixer accelerates the natural diffusion process to mix the different fluid streams. Finally, a 3D numerical simulation of the passive micromixer was carried out to visualize the flow dynamics inside the micromixer. The flow pattern found from the numerical simulation and the experimental flow characterization is analogous. These observations could play an important role to design and fabricate cost-effective micromixers for lab-on-a-chip devices.

Detailed numerical simulation and experimental investigation on micromixers with serpentine Koch fractal microchannels

Micromixer is a kind of microfluidic chip for fast mixing and analysis. Mixing in a micromixer is usually a micron scale. At low Reynolds number, the fluid in the channel is laminar flow, which mainly depends on molecular diffusion as the main mixing mode. Fluid mixing in microchannels is very difficult, especially when the viscosity of the fluid is high. In this paper, we design a novel passive micromixer. The effects of fractal number, Koch fractal channel spacing, microchannel depth and cross-section shape on mixing efficiency were studied. Through a large number of numerical simulations, we continue to optimize the structure of the micromixer and improve the mixing efficiency. Finally, through the continuous optimization of the structure of the micromixer, the mixing efficiency of the micromixer can reach more than 95%.

Rapid Microfluidic Mixing Method Based on Droplet Rotation Due to PDMS Deformation

Droplet-based micromixers have shown great prospects in chemical synthesis, pharmacology, biologics, and diagnostics. When compared with the active method, passive micromixer is widely used because it relies on the droplet movement in the microchannel without extra energy, which is more concise and easier to operate. Here we present a droplet rotation-based microfluidic mixer that allows rapid mixing within individual droplets efficiently. PDMS deformation is used to construct subsidence on the roof of the microchannel, which can deviate the trajectory of droplets. Thus, the droplet shows a rotation behavior due to the non-uniform distribution of the flow field, which can introduce turbulence and induce cross-flow enhancing 3D mixing inside the droplet, achieving rapid and homogenous fluid mixing. In order to evaluate the performance of the droplet rotation-based microfluidic mixer, droplets with highly viscous fluid (60% w/w PEGDA solution) were generated, half of which was seeded with fluorescent dye for imaging. Mixing efficiency was quantified using the mixing index (MI), which shows as high as 92% mixing index was achieved within 12 mm traveling. Here in this work, it has been demonstrated that the microfluidic mixing method based on the droplet rotation has shown the advantages of low-cost, easy to operate, and high mixing efficiency. It is expected to find wide applications in the field of pharmaceutics, chemical synthesis, and biologics.

Characterization of Mixing Performance Induced by Double Curved Passive Mixing Structures in Microfluidic Channels

Functionalized sensor surfaces combined with microfluidic channels are becoming increasingly important in realizing efficient biosensing devices applicable to small sample volumes. Relaxing the limitations imposed by laminar flow of the microfluidic channels by passive mixing structures to enhance analyte mass transfer to the sensing area will further improve the performance of these devices. In this paper, we characterize the flow performance in a group of microfluidic flow channels with novel double curved passive mixing structures (DCMS) fabricated in the ceiling. The experimental strategy includes confocal imaging to monitor the stationary flow patterns downstream from the inlet where a fluorophore is included in one of the inlets in a Y-channel microfluidic device. Analyses of the fluorescence pattern projected both along the channel and transverse to the flow direction monitored details in the developing homogenization. The mixing index (MI) as a function of the channel length was found to be well accounted for by a double-exponential equilibration process, where the different parameters of the DCMS were found to affect the extent and length of the initial mixing component. The range of MI for a 1 cm channel length for the DCMS was 0.75–0.98, which is a range of MI comparable to micromixers with herringbone structures. Overall, this indicates that the DCMS is a high performing passive micromixer, but the sensitivity to geometric parameter values calls for the selection of certain values for the most efficient mixing.