Passive Micromixer Research Articles

Optimization of three-dimensional Tesla valve-based passive micromixer for gradient functional materials mixing

With the rapid development of three-dimensional (3D) printing technology, the field of multi-material fabrication, particularly in the production of functionally graded materials, has achieved revolutionary advancements. However, the structures of micromixers, which are central to this technology, have not been sufficiently studied. This study introduces an optimized passive micromixer design based on a 3D Tesla valve, specifically engineered for the efficient mixing of Fe3O4 particles within an epoxy resin E51 matrix. The micromixer leverages the fluid dynamics of the Tesla valve, where sudden changes in flow direction generate secondary flows that enhance mixing performance by disrupting laminar flow and inducing chaotic advection, thereby increasing the interfacial area between different material components. This process significantly improves mixing efficiency in the fabrication of gradient materials. Through theoretical analysis and computational simulations, the study identifies optimal configurations for the Tesla valve system, emphasizing mixing dynamics that enhance material gradient formation. The findings reveal that optimal mixing efficiency is achieved with a configuration comprising three Tesla valves. This optimal setup includes a 0.5-mm opening width at the turning point, an immediate transition from the turning point to the straight pipe (0 mm length), a 0.25-mm structural height for the Tesla valve, and an outlet distance of 0.25 mm from the curved pipe. Hopefully, this study can provide a robust reference for the significant potential of future applications in the realm of multi-material 3D printing, thereby fostering its substantial growth prospects.

Characterization of the oil water two phase flow in a novel microchannel contactor equipped with helical wire static mixer

This study investigates an oil/water two-phase system to assess the potential efficacy of a novel passive mixer in enhancing the liquid-liquid interfacial area within a micro-channel contactor. In this system, two fluids are introduced into a microchannel with a diameter of 800 μm and a length of 20 cm, which is equipped with a stainless-steel helical wire measuring 250 μm in diameter. Throughout the experiments, both fluids are supplied at equal flow rates, and the dominant forces, including attachment and detachment forces, are examined. The results reveal a critical Weber number of 3.8 × 10−³, at which the first detachment occurs. A comparison between microchannels with and without the passive micromixer demonstrates that greater slug breakup occurs in the system incorporating the helical wire micromixer. This innovative configuration results in a significant reduction in slug/droplet size compared to a microchannel without a barrier, decreasing from approximately 600 μm to 390 μm at a flow rate of 0.8 mL/min. Additionally, a flow map is presented, illustrating three distinct flow regimes: flow contains long slug, Slug-droplet flow, and droplet flow regimes, with the droplet flow regime covering the largest area. The findings indicate that the implementation of this innovative passive mixer substantially increases the interfacial area, providing significant advantages for mass transfer applications.

Inertial microfluidic mixer for biological CubeSat missions

Nanosatellites of CubeSat type due to, i.a., minimized costs of space missions, as well as the potential large application area, have become a significant part of the space economy sector recently. The opportunity to apply miniaturized microsystem (MEMS) tools in satellite space missions further accelerates both the space and the MEMS markets, which in the coming years are considered to become inseparable. As a response to the aforementioned perspectives, this paper presents a microfluidic mixer system for biological research to be conducted onboard CubeSat nanosatellites. As a high complexity of the space systems is not desired due to the need for failure-free and remotely controlled operation, the principal concept of the work was to design an entirely passive micromixer, based on lab-on-chip technologies. For the first time, the microfluidic mixer that uses inertial force generated by rocket engines during launch to the orbit is proposed to provide an appropriate mixing of liquid samples. Such a solution not only saves the space occupied by standard pumping systems, but also reduces the energy requirements, ultimately minimizing the number of battery modules and the whole CubeSat size. The structures of the microfluidic mixers were fabricated entirely out of biocompatible resins using MultiJet 3D printing technology. To verify the functionality of the passive mixing system, optical detection consisting of the array of blue LEDs and phototransistors was applied successfully. The performance of the device was tested utilizing an experimental rocket, as a part of the Spaceport America Cup 2023 competition.Graphical abstract

A comprehensive review on the fundamental principles, innovative designs, and multidisciplinary applications of micromixers

This paper comprehensively reviews the fundamental principles, innovative designs, and multidisciplinary applications of micromixers. First, it introduces the fundamental principles of fluid mixing in micromixers, including passive and active mixing mechanisms, and the flow characteristics of fluids at the microscale. Subsequently, it focuses on the innovative design of passive micromixers, covering a variety of designs, such as obstacle structures, curved serpentine structures, groove structures, separation and recombination structures, topology optimization structures, and baffle structures, and analyzes the effects of different structures on mixing efficiency and pressure drop. In addition, it also studies the innovative design of active micromixers, including magnetic field assistance, electric field assistance, surface acoustic wave assistance, and thermal effect assistance, and analyzes the effects of different driving modes on mixing efficiency. Finally, it outlines the multidisciplinary applications of micromixers in the fields of biomedicine, chemical analysis, environmental monitoring and control, and new energy. This review aims to provide a comprehensive reference for the research and application of micromixers and promote their application in more fields.

Enhancing the performance of porous silicon biosensors: the interplay of nanostructure design and microfluidic integration

This work presents the development and design of aptasensor employing porous silicon (PSi) Fabry‒Pérot thin films that are suitable for use as optical transducers for the detection of lactoferrin (LF), which is a protein biomarker secreted at elevated levels during gastrointestinal (GI) inflammatory disorders such as inflammatory bowel disease and chronic pancreatitis. To overcome the primary limitation associated with PSi biosensors—namely, their relatively poor sensitivity due to issues related to complex mass transfer phenomena and reaction kinetics—we employed two strategic approaches: First, we sought to optimize the porous nanostructure with respect to factors including layer thickness, pore diameter, and capture probe density. Second, we leveraged convection properties by integrating the resulting biosensor into a 3D-printed microfluidic system that also had one of two different micromixer architectures (i.e., staggered herringbone micromixers or microimpellers) embedded. We demonstrated that tailoring the PSi aptasensor significantly improved its performance, achieving a limit of detection (LOD) of 50 nM—which is >1 order of magnitude lower than that achieved using previously-developed biosensors of this type. Moreover, integration into microfluidic systems that incorporated passive and active micromixers further enhanced the aptasensor’s sensitivity, achieving an additional reduction in the LOD by yet another order of magnitude. These advancements demonstrate the potential of combining PSi-based optical transducers with microfluidic technology to create sensitive label-free biosensing platforms for the detection of GI inflammatory biomarkers.

Optimization of passive micromixers: effects of pillar configuration and gaps on mixing efficiency

Chemical bioreactions play a significant role in many of the microfluidic devices, and their applications in biomedical science have seen substantial growth. Given that effective mixing is vital for initiating biochemical reactions in many applications, micromixers have become increasingly prevalent for high-throughput assays. In this research, a numerical study using the finite element method was conducted to examine the fluid flow and mass transfer characteristics in novel micromixers featuring an array of pillars. The study utilized two-dimensional geometries. The impact of pillar configuration on mixing performance was evaluated using concentration distribution and mixing index as key metrics. The study explores the effects of pillar array design on mixing performance and pressure drop, drawing from principles such as contraction–expansion and split-recombine. Two configurations of pillar arrays, slanted and arrowhead, are introduced, each undergoing investigation regarding parameters such as pillar diameter, gap size between pillar groups, distance between pillars, and vertical shift in pillar groups. Subsequently, optimal micromixers are identified, exhibiting mixing efficiency exceeding 99.7% at moderate Reynolds number (Re = 1), a level typically challenging for micromixers to attain high mixing efficiency. Notably, the pressure drop remains low at 1102 Pa. Furthermore, the variations in mixing index over time and across different positions along the channel are examined. Both configurations demonstrate short mixing lengths and times. At a distance of 4300 μm from the inlet, the slanted and arrowhead configurations yielded mixing indices of 97.2% and 98.9%, respectively. The micromixers could provide a mixing index of 99.5% at the channel’s end within 8 s. Additionally, both configurations exceeded 90% mixing indices by the 3 s. The combination of rapid mixing, low pressure drop, and short mixing length positions the novel micromixers as highly promising for microfluidic applications.

Thermal and Hydrodynamic Measurements of a Novel Chaotic Micromixer to Enhance Mixing Performance

In this study, three-dimensional simulations were conducted on a new passive micromixer to assess the thermal and hydrodynamic behaviors of Newtonian and non-Newtonian fluids subjected to low generalized Reynolds numbers (0.1 to 50) and shear-thinning properties. To acquire a more profound comprehension of the qualitative and quantitative fluctuations in fluid fraction using the CFD Fluent Code, the mass mixing index, rheological behavior, performance index, mixing energy cost, mass fraction distributions, temperature contours, and pressure drop were compared to illustrate the importance of the mixer geometry in the context of two miscible fluids with varying inlet temperatures. The selected geometry is characterized by a robust chaotic flow that substantially enhances thermal and hydrodynamic performance across all Reynolds numbers. A mass mixing exceeding 72.5% is obtained when Re = 5, reaching 93.5% when Re = 50. Furthermore, the evolution of thermal mixing for all behavior indexes reaches a step of 98% with minimal pressure losses. This work enabled the demonstration of a chaotic geometry in a highly efficient mixing system, leading to enhanced thermal performance for both Newtonian and non-Newtonian fluids. The results of the hydrodynamic and thermal characterization of the mixing of shear-thinning fluids within the micromixers under investigation are conclusive.

Design and Mixing Analysis of a Passive Micromixer with Circulation Promoters.

A novel passive micromixer equipped with circulation promoters is proposed, and its mixing performance is simulated over a broad range of Reynolds numbers (0.1≤Re≤100). To evaluate the effectiveness of the circulation promoters, three different configurations are analyzed in terms of the degree of mixing (DOM) at the outlet and the associated pressure drop. Compared to other typical passive micromixers, the circulation promoter is shown to significantly enhance mixing performance. Among the three configurations of circulation promoters, Case 3 demonstrates the best performance, with a DOM exceeding 0.96 across the entire range of Reynolds numbers. At Re = 1, the DOM of Case 3 is 3.7 times larger than that of a modified Tesla micromixer, while maintaining a comparable pressure drop. The mixing enhancement of the present micromixer is particularly significant in the low and intermediate ranges of Reynolds numbers (Re<40). In the low range of Reynolds numbers (Re≤1), the mixing enhancement is primarily due to circulation promoters directing fluid flow from a concave wall to the opposite convex wall. In the intermediate range of Reynolds numbers (2≤Re<40), the mixing enhancement results from fluid flowing from one concave wall to another concave wall on the opposite side.

Mixing Performance of a Passive Micromixer Based on Split-to-Circulate (STC) Flow Characteristics.

We propose a novel passive micromixer leveraging STC (split-to-circulate) flow characteristics and analyze its mixing performance comprehensively. Three distinct designs incorporating submerged circular walls were explored to achieve STC flow characteristics, facilitating flow along a convex surface and flow impingement on a concave surface. Across a broad Reynolds number range (0.1 to 80), the present micromixer substantially enhances mixing, with a degree of mixing (DOM) consistently exceeding 0.84. Particularly, the mixing enhancement is prominent within the low and intermediate range of Reynolds numbers (0.1<Re<20). This enhancement stems from key flow characteristics of STC: the formation of saddle points around convex walls and flow impingement on concave walls. Compared to other passive micromixers, the DOM of the present micromixer stands out as notably high over a broad range of Reynolds numbers (0.1≤Re≤80).

A Review of Pressure Drop and Mixing Characteristics in Passive Mixers Involving Miscible Liquids.

The present review focuses on the recent studies carried out in passive micromixers for understanding the hydrodynamics and transport phenomena of miscible liquid-liquid (LL) systems in terms of pressure drop and mixing indices. First, the passive micromixers have been categorized based on the type of complexity in shape, size, and configuration. It is observed that the use of different aspect ratios of the microchannel width, presence of obstructions, flow and operating conditions, and fluid properties majorly affect the mixing characteristics and pressure drop in passive micromixers. A regime map for the micromixer selection based on optimization of mixing index (MI) and pressure drop has been identified based on the literature data for the Reynolds number (Re) range (1 ≤ Re ≤ 100). The map comprehensively summarizes the favorable, moderately favorable, or non-operable regimes of a micromixer. Further, regions for special applications of complex micromixer shapes and micromixers operating at low Re have been identified. Similarly, the operable limits for a micromixer based on pressure drop for Re range 0.1 < Re < 100,000 have been identified. A comparison of measured pressure drop with fundamentally derived analytical expressions show that Category 3 and 4 micromixers mostly have higher pressure drops, except for a few efficient ones. An MI regime map comprising diffusion, chaotic advection, and mixed advection-dominated zones has also been devised. An empirical correlation for pressure drop as a function of Reynolds number has been developed and a corresponding friction factor has been obtained. Predictions on heat and mass transfer based on analogies in micromixers have also been proposed.

Experimental and numerical assessment and performance optimization of a novel T-arrow microfluidic device to mix two fluids with different thermophysical properties

Micromixers are critical parts of integrated microfluidic systems and their performance improvement has been a crucial problem for many investigators. Since the mixing enhancement in passive micromixers is hindered by the low-Reynolds number regime, multiple inlets have been recommended to create chaotic advection and improve the mixing quality. In this paper, a novel T-arrow micromixer is introduced to augment the mixing index (MI) of two liquids with different thermophysical properties. Numerical and experimental investigations are carried out by changing the distance between the inlets (a), the angle of the arrow-shaped inlet (α), the velocity ratio (VR), and the width-to-height aspect ratio (AR). Five optimization algorithms are also utilized to optimize the micromixer performance to achieve the most appropriate geometrical characteristics. It is found that MI is enhanced significantly by adding a Y-type inlet compared to a T-shaped mixer. The results demonstrate that while MI declines with a, there are optimal values for α, VR, and AR. Besides, parallel optimization of MI and pressure drop recommends two optimal micromixers with mixing energy cost (MEC) of 2841 Pa and 3370 Pa.

Analysis of vortex mixing in passive micromixers with misaligned inlet and rectangular winglets

In the present study, a three-dimensional design of a passive micromixer is proposed which induces the swirling flow pattern by employing the misaligned inlets and winglets. The concepts of fluid stretching and twisting are utilized to improve the mixing efficiency. Stretching is quantified in terms of the modified flow tortuosity parameter. The dependence of various geometrical parameters on flow tortuosity is examined to increase the diffusive mixing by increasing the lateral Peclet number. A detailed analysis is carried out to understand the impact of geometrical features on the vortex formation, propagation, and intensification. Lambda 2 and the helicity approach are used to identify the vortex core region and quantified using a modified swirl number & vortex index. For vortex T misalignment, the aspect ratio 1 along with the staggered common flow-down configuration of winglets is highly effective. For misaligned Y inlet, both interfacial diffusive mixing along with longitudinal vortices at winglets generate highly effective mixing even at a low Reynolds number. For Reynolds number 1 to 70 and channel length 3.5 mm, mixing efficiency above 82% is achieved, and the mixing energy cost is subsequently reduced. A detailed comparative study is done to establish the effectiveness of the present design.

Mixing performance of T-shaped wavy-walled micromixers with embedded obstacles

This research systematically investigates the impact of microchannel geometry on key parameters governing mixing efficiency and cost. The study focuses on passive T-shaped micromixers with modified sinusoidal wavy walls, analyzing a spectrum of configurations ranging from the raccoon to serpentine by varying the wall phase angles. The traditional T-shaped micromixer serves as a foundational reference, and we systematically vary phase angles, amplitudes, and wavelengths of the wavy walls to comprehensively address all possible configurations. Additionally, different shaped obstacles such as circular, square, diamond, and triangular obstacles are strategically introduced to further enhance mixing performance. The findings reveal intricate relationships and dependencies among geometric factors, shedding light on configurations that significantly enhance mixing efficiencies. Notably, a specific wavy micromixer configuration, characterized by a carefully tuned phase difference, amplitude, and wavelength, exhibits the highest mixing index in the absence of obstacles. The introduction of obstacles, particularly circular ones, further enhances mixing efficiency. As Reynolds (Re) and Schmidt (Sc) numbers increase, the mixing index decreases, and the mixing cost rises. This work adds a quantitative dimension to understanding the interplay between geometric parameters, flow conditions, and mixing performance in passive micromixers with systematic wavy walls and embedded obstacles.

Numerical Investigation on a Chaotic Passive Micromixer Based on Square Chambers Connected with Different Channel Shapes for Enhancing the Mixing Process

Numerical Investigation on a Chaotic Passive Micromixer Based on Square Chambers Connected with Different Channel Shapes for Enhancing the Mixing Process

Simulation study on the effect of hydro-active patches in passive micromixer geometry for fluid flow and mixing

Simulation study on the effect of hydro-active patches in passive micromixer geometry for fluid flow and mixing

Mixing Performance Analysis and Optimal Design of a Novel Passive Baffle Micromixer.

Micromixers, as crucial components of microfluidic devices, find widespread applications in the field of biochemistry. Due to the laminar flow in microchannels, mixing is challenging, and it significantly impacts the efficiency of rapid reactions. In this study, numerical simulations of four baffle micromixer structures were carried out at different Reynolds numbers (Re = 0.1, Re = 1, Re = 10, and Re = 100) in order to investigate the flow characteristics and mixing mechanism under different structures and optimize the micromixer by varying the vertical displacement of the baffle, the rotation angle, the horizontal spacing, and the number of baffle, and by taking into account the mixing intensity and pressure drop. The results indicated that the optimal mixing efficiency was achieved when the baffle's vertical displacement was 90 μm, the baffle angle was 60°, the horizontal spacing was 130 μm, and there were 20 sets of baffles. At Re = 0.1, the mixing efficiency reached 99.4%, and, as Re increased, the mixing efficiency showed a trend of, first, decreasing and then increasing. At Re = 100, the mixing efficiency was 97.2%. Through simulation analysis of the mixing process, the structure of the baffle-type micromixer was effectively improved, contributing to enhanced fluid mixing efficiency and reaction speed.

Versatile hybrid technique for passive straight micromixer manufacturing by combining pulsed laser ablation, stereolithographic 3D printing and computational fluid dynamics.

There is a need to develop new and versatile fabrication methods to achieve efficient mixing of fluids in microfluidic channels using microstructures. This work presents a new technique that combines stereolithography (SLA) and pulsed laser ablation (PLA) to manufacture a straight micromixer for uniform mixing of two samples. Computational fluid dynamics (CFD) simulation is performed to deeply understand the physical mechanisms of the process. The results suggest that this new optical technique holds the potential to become a versatile hybrid technique for manufacturing remarkable mixing microfluidic devices.

Performance of a helical insert in a commercial tubing as a passive micromixer to produce nanoparticles using an emulsification approach

This work highlights novel helical inserts as micromixers with interesting features: straightforward to adapt to a conventional tubing, high mixing efficiency and complete regeneration in the case of fouling as it can be disassembled from the tubing.

Micromixing within microfluidic devices: Fundamentals, design, and fabrication

As one of the hot spots in the field of microfluidic chip research, micromixers have been widely used in chemistry, biology, and medicine due to their small size, fast response time, and low reagent consumption. However, at low Reynolds numbers, the fluid motion relies mainly on the diffusive motion of molecules under laminar flow conditions. The detrimental effect of laminar flow leads to difficulties in achieving rapid and efficient mixing of fluids in microchannels. Therefore, it is necessary to enhance fluid mixing by employing some external means. In this paper, the classification and mixing principles of passive (T-type, Y-type, obstructed, serpentine, three-dimensional) and active (acoustic, electric, pressure, thermal, magnetic field) micromixers are reviewed based on the presence or absence of external forces in the micromixers, and some experiments and applications of each type of micromixer are briefly discussed. Finally, the future development trends of micromixers are summarized.

Numerical study of mixing performance in T-junction passive micromixer with twisted design

In this study, numerical computations are performed with the main purpose of shedding light on the mixing characteristics in an innovative T-shaped micromixer equipped with a twisted structure. A 3-D model is presented and verified to mix two miscible fluids in a single phase. By considering different geometrical cases, the proposed T-mixer is compared using the standard T-mixer (Base case) running in the same operational conditions. Furthermore, the impacts of variation in the geometry of twisted design are scrutinized for Re (Reynolds number) in the extent of 1≤Re≤500 with the focus of obtaining a significant mixing quality for flow through the micromixer. MI (Mixing index), PI (performance index), and pressure drop are evaluated for micromixers with and without twisted patterns considering various values of Reynolds number. The numerical outcomes demonstrate that the MI (mixing performance) and PI (performance index) improve remarkably for T-shaped microchannel with twisted patterns, particularly Re`=200, due to the geometry of the curvature and the presence of secondary flow in the mixer. It is also found that case 6 yields the greatest improvement in mixing implementation by increasing the mixing index up to 142 percent.