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1. Robust Microfabrication of Highly Parallelized Three-Dimensional Microfluidics on Silicon

   https://doi.org/10.1038/s41598-019-48515-4  

   Yadavali, Sagar ; Lee, Daeyeon ; Issadore, David ( August 2019 , Scientific Reports)

   We present a new, robust three dimensional microfabrication method for highly parallel microfluidics, to improve the throughput of on-chip material synthesis by allowing parallel and simultaneous operation of many replicate devices on a single chip. Recently, parallelized microfluidic chips fabricated in Silicon and glass have been developed to increase the throughput of microfluidic materials synthesis to an industrially relevant scale. These parallelized microfluidic chips require large arrays (>10,000) of Through Silicon Vias (TSVs) to deliver fluid from delivery channels to the parallelized devices. Ideally, these TSVs should have a small footprint to allow a high density of features to be packed into a single chip, have channels on both sides of the wafer, and at the same time minimize debris generation and wafer warping to enable permanent bonding of the device to glass. Because of these requirements and challenges, previous approaches cannot be easily applied to produce three dimensional microfluidic chips with a large array of TSVs. To address these issues, in this paper we report a fabrication strategy for the robust fabrication of three-dimensional Silicon microfluidic chips consisting of a dense array of TSVs, designed specifically for highly parallelized microfluidics. In particular, we have developed a two-layer TSVmore »design that allows small diameter vias (d < 20 µm) without sacrificing the mechanical stability of the chip and a patterned SiO₂etch-stop layer to replace the use of carrier wafers in Deep Reactive Ion Etching (DRIE). Our microfabrication strategy allows >50,000 (d = 15 µm) TSVs to be fabricated on a single 4” wafer, using only conventional semiconductor fabrication equipment, with 100% yield (M = 16 chips) compared to 30% using previous approaches. We demonstrated the utility of these fabrication strategies by developing a chip that incorporates 20,160 flow focusing droplet generators onto a single 4” Silicon wafer, representing a 100% increase in the total number of droplet generators than previously reported. To demonstrate the utility of this chip for generating pharmaceutical microparticle formulations, we generated 5–9 µm polycaprolactone particles with a CV < 5% at a rate as high as 60 g/hr (>1 trillion particles/hour).

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2. A bioinspired, passive microfluidic lobe filtration system

   https://doi.org/10.1039/D1LC00449B  

   Clark, Andrew S. ; San-Miguel, Adriana ( September 2021 , Lab on a Chip)

   Size-based microfluidic filtration systems can be affected by clogging, which prevents their use in high-throughput and continuous applications. To address these concerns, we have developed two microfluidic lobe filters bioinspired by the filtration mechanism of two species of manta ray. These chips enable filtration of particles around 10–30 μm with precise control and high throughput by using two arrays of equally spaced filter lobes. For each filter design, we investigated multiple inlet flow rates and particle sizes to identify successful operational parameters. Filtration efficiency increases with fluid flow rate, suggesting that particle inertial effects play a key role in lobe filter separation. Microparticle filtration efficiencies up to 99% were obtainable with inlet flow rates of 20 mL min −1 . Each filter design successfully increased microparticle concentrations by a factor of two or greater at different inlet flow rates ranging from 6–16 mL min −1 . At higher inlet flow rates, ANSYS Fluent simulations of each device revealed a complex velocity profile that contains three local maxima and two inflection points. Ultimately, we show that distances from the lobe array to the closest local maxima and inflection point of the velocity profile can be used to successfully estimate lobe filtrationmore »efficiency at each operational flow rate.« less
3. Narrow equilibrium window for complex coacervation of tau and RNA under cellular conditions

   https://doi.org/10.7554/eLife.42571  

   Lin, Yanxian ; McCarty, James ; Rauch, Jennifer N ; Delaney, Kris T ; Kosik, Kenneth S ; Fredrickson, Glenn H ; Shea, Joan-Emma ; Han, Songi ( April 2019 , eLife)

   Proteins make up much of the machinery of cells and perform many roles that are essential for life. Some important proteins – known as intrinsically disordered proteins – lack any stable three-dimensional structure. One such protein, called tau, is best known for its ability to form tangles in the brain, and a buildup of these tangles is a hallmark of Alzheimer’s disease and many other dementias. Tau is also one of a number of proteins that can undergo a process called liquid-liquid phase separation: essentially, a solution of tau separates into a very dilute solution interspersed with droplets of a concentrated tau solution, similar to an oil-water mixture separating into a very watery solution with drops of oil. Understanding the conditions that lead to spontaneous liquid-liquid phase separation might give insight into how the tau tangles form. However, it was not known whether it is possible in principle for liquid-liquid phase separation of tau to occur in a living brain. Lin, McCarty et al. have now used an advanced computer simulation method together with experiments to map the conditions under which a solution containing tau undergoes liquid-liquid phase separation. Temperature as well as the concentrations of salt and the taumore »protein all influenced how easily tau droplets formed or dissolved, and the narrow range of conditions that encouraged droplet formation fell within the normal conditions found in the body, also known as “physiological conditions”. This suggested that tau droplets might form and dissolve easily in living systems, and possibly in the brain, depending on the precise physiological conditions. To explore this possibility further, tau protein was added to a dish containing living cells. As the map suggested, slightly adjusting temperature or protein concentrations caused tau droplets to form and dissolve, all while the cells remained alive. The map provided by this study may offer guides to researchers looking for liquid-liquid phase separation in the brain. If liquid-liquid phase separation of tau occurs in living brains, it may be important for determining whether and when damaging tau tangles emerge. For example, the high concentration of tau in droplets might speed up tangle formation. Ultimately, a better understanding of the conditions and mechanism for liquid-liquid phase separation of tau can help researchers understand the role of protein droplet formation in living systems. This may be a process that promotes, or possibly a regulatory mechanism that prevents, the formation of tau tangles associated with dementia.« less
4. Importance of Body Stance in Fog Droplet Collection by the Namib Desert Beetle

   https://doi.org/10.3390/biomimetics4030059  

   Chakrabarti, Unmeelan ; Paoli, Roberto ; Chatterjee, Souvick ; Megaridis, Constantine M. ( September 2019 , Biomimetics)

   The fog-basking behavior of the Onymacris unguicularis, a beetle species living in the coastal regions of the Namibian desert, has recently caught the attention of the engineering community, as suggesting a viable biomimetic approach to address the problem of harvesting water in arid regions of the globe. Previous research has focused on observation and analysis of the beetle’s elytron properties and how these affect fog-collection rates. The head stance taken by the Onymacris unguicularis when fog basking is well documented. However, how this stance affects droplet collection has not been studied up to now. The present paper addresses this problem from a computational fluid dynamics perspective, where three-dimensional numerical simulations are used to characterize the fog flow properties around a simplified geometry mimicking the beetle’s body. The simulations employ two-way coupling between the gas flow and the dispersed fog phase to account for feedback effects of fog droplets on the carrier fluid (air), and assume that droplets are captured after hitting the elytron surface. The study considers several combinations of free-stream velocity and droplet volume fraction. The analysis reveals that there is a range of head-stance angles, corresponding to an inclination of the beetle between 35 deg and 45 degmore »with respect to the horizon, that maximizes water collection on the beetle’s back, in qualitative agreement with observations in nature and laboratory experiments. A rationale is proposed to explain this phenomenon, finding that the specific head stance corresponds to the maximum residence time of fluid particles above the beetle’s elytron surface. This, in turn, designates the maximum likelihood for water droplets to be captured in the boundary layer developing over the beetle and subsequently hit the surface where they get captured. The results reveal the importance of the fluid flow pattern around the beetle’s body in addition to the microphysical properties of the elytron when reliable predictions of the water droplet collection efficiency are sought.« less
5. Effect of Reynolds number on aerobreakup of small liquid drops

   Mahmood, T. ; Ling, Y. ( August 2021 , ICLASS 2021, 15th Triennial International Conference on Liquid Atomization and Spray Systems, Edinburgh, UK)

   Aerobreakup of liquid drops are important to many droplet applications, such as fuel injection. When a liquid drop is subjected to a gas stream of high velocity, the drop can deform and break into small droplets. The drop aerobreakup is controlled by multiple dimensionless parameters. The Weber number (We) has been commonly used to characterize the different breakup regimes. While the effects of Weber and Ohnesorge numbers on the aerobreakup of a drop in unbounded domain have been extensively studied, the effect of the Reynolds number (Re) based on gas properties are less understood and will be investigated by 2D axis-symmetric and 3D detailed numerical simulations in the present paper. Attention will be focused on the moderate We regime, where the drop mostly breaks in the bag mode. In many previous studies for millimeter drops, Re is too large to be relevant. However, for applications where drops are small and the relative velocity is high, Re can be quite small when the drop breaks. Parametric simulations of Re and We are performed to systematically investigate the effect of Re on the drop aerobreakup dynamics. The simulations are performed using the Basilisk solver, where the mass-momentum consistent VOF method is usedmore »to capture the interfacial dynamics on an adaptive mesh. The reduced Re is found to induce significant changes in the drop acceleration, deformation, bag morphology, and the bag breakup dynamics, which in turn lead to significant variation in the size and spatial distributions of the children droplets formed.« less