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Journal = Micromachines
Section = C:Chemistry

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25 pages, 3533 KB  
Article
Ultrasensitive Hydrogen Detection Using GNRFET Sensor: Multimetric Optimization via Geometry, Temperature, and Oxygen Environment
by Mohammad K. Anvarifard and Zeinab Ramezani
Micromachines 2026, 17(5), 632; https://doi.org/10.3390/mi17050632 - 21 May 2026
Viewed by 111
Abstract
This work presents a comprehensive analysis of a Palladium (Pd)-gated graphene nanoribbon field-effect transistor (GNRFET) as a high-sensitivity potential hydrogen sensor under idealized conditions, focusing on the structural and environmental control of multimetric sensitivity. Hydrogen adsorption is modeled through pressure-dependent work-function modulation and [...] Read more.
This work presents a comprehensive analysis of a Palladium (Pd)-gated graphene nanoribbon field-effect transistor (GNRFET) as a high-sensitivity potential hydrogen sensor under idealized conditions, focusing on the structural and environmental control of multimetric sensitivity. Hydrogen adsorption is modeled through pressure-dependent work-function modulation and interface coverage, including competition with oxygen. For hydrogen gas at a pressure of PH2=106 Torr without O2, the sensor exhibits a maximum threshold voltage sensitivity of about 300 mV, which is reduced to roughly 40 mV under an oxygen partial pressure of 152 Torr, quantifying the impact of background gas on response. Band diagrams, transmission spectra, local density of states, and transfer characteristics are examined over wide ranges of H2 pressure, temperature, gate length, and nanoribbon width. Sensitivity is evaluated using drain current change, threshold voltage shift, and average subthreshold swing variation. Results showed that the sensitivity based on current is high for ultralow hydrogen pressures, whereas it is low in higher levels of pressure compared to the sensitivity based on subthreshold. Also, uncertainty analysis revealed that the threshold voltage metric remains largely geometry-independent and thus tolerant to fabrication variations. Full article
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15 pages, 15745 KB  
Article
Thermal Recovery of Damaged Hydrophobic Coatings in EWOD Devices Using an Integrated Mesh-Patterned Heater
by Youngdoo Son, Woochan Kim, Youngkwang Kim, Daeyoung Lee and Sangkug Chung
Micromachines 2026, 17(5), 631; https://doi.org/10.3390/mi17050631 - 21 May 2026
Viewed by 132
Abstract
We propose an integrated electrowetting-on-dielectric (EWOD) device incorporating a mesh-patterned heater to restore damaged hydrophobic coatings and evaluate its recovery performance. Hydrophobic degradation was induced under submersion and falling droplet conditions, and the damage and recovery mechanisms of the coating were examined. A [...] Read more.
We propose an integrated electrowetting-on-dielectric (EWOD) device incorporating a mesh-patterned heater to restore damaged hydrophobic coatings and evaluate its recovery performance. Hydrophobic degradation was induced under submersion and falling droplet conditions, and the damage and recovery mechanisms of the coating were examined. A damaged Cytop (CTL-809M) coating was thermally treated using the embedded heater at 200 °C for 24 h, successfully restoring its hydrophobicity. Coating properties before and after recovery were characterized by contact angle (CA) and contact angle hysteresis (CAH) measurements, evaluating EWOD performance and surface analyses using atomic force microscopy (AFM) and X-ray photoelectron spectroscopy (XPS). After treatment, the reduced CA and increased CAH were recovered, and wetting/dewetting performance in EWOD operation also recovered to pre-damage levels. AFM and XPS analyses confirmed the simultaneous restoration of the surface morphology and chemical composition. These results demonstrate a practical approach for restoring hydrophobic coatings within EWOD devices and offering a promising solution for improving device reliability and lifetime in applications related to EWOD. Full article
(This article belongs to the Special Issue Microfluidic Systems for Sustainable Energy)
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15 pages, 2225 KB  
Article
Portable and Point-of-Care Testing Approach for Determining Soil Extracellular Enzyme Activities
by Xu Han, Fangzhou Zhang, Ruirui Chen, Weixin Wang, Yongjie Yu, Zaijiong Yi, Jingyi Yang, Bo Liu, Shilun Feng, Jun Li and Youzhi Feng
Micromachines 2026, 17(5), 599; https://doi.org/10.3390/mi17050599 - 14 May 2026
Viewed by 170
Abstract
Soil eco-enzymes (i.e., microbial extracellular enzymes) play essential roles in terrestrial nutrient cycling and support ecosystem services. In this regard, their activities serve as indicators of soil health. However, conventional spectrophotometric and microplate fluorometric assays are often limited by lengthy reaction procedures, relatively [...] Read more.
Soil eco-enzymes (i.e., microbial extracellular enzymes) play essential roles in terrestrial nutrient cycling and support ecosystem services. In this regard, their activities serve as indicators of soil health. However, conventional spectrophotometric and microplate fluorometric assays are often limited by lengthy reaction procedures, relatively high reagent consumption, and insufficient compatibility with complex soil matrices. In this investigation, we developed a portable, centrifugally driven microfluidic chip for the rapid and sensitive determination of multiple soil extracellular enzyme activities. This integrated platform automated sample aliquoting, reagent metering, mixing, and sedimentation, enabling the parallel measurement of eight enzymes. Such system demonstrated precise liquid control via capillary valves and high optical uniformity (<5% fluorescence variation). 4-methylumbelliferone (MUF)-based calibration exhibited strong linearity (R2 > 0.99) across diverse soil types. Compared with conventional microplate assays, the microfluidic method improved reproducibility (CV < 15%), enhanced the detection of weak fluorescence signals, and increased throughput while reducing reagent consumption. This field-ready platform provides a robust solution for standardized soil enzyme assessment and offers future potential for integration with AI-driven data analytics and large-scale ecological monitoring frameworks. Full article
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16 pages, 4525 KB  
Article
Stretchable Textile-Based Membraneless Microfluidic Microalgae–Microbial Solar Cell
by Hui Geon Kong, Yeon Woo Cha, Sang Hyuk Lee, Injun Song and Yoomin Ahn
Micromachines 2026, 17(5), 593; https://doi.org/10.3390/mi17050593 - 13 May 2026
Viewed by 242
Abstract
A textile-based membraneless microfluidic microalgae–microbial solar cell (μmMSC) was developed for low-cost, flexible, and sustainable power generation. Unlike conventional systems, the proposed device utilizes a textile substrate, enabling mechanical flexibility and simplified fabrication. Microfluidic channels were patterned via screen printing using hydrophobic Ecoflex, [...] Read more.
A textile-based membraneless microfluidic microalgae–microbial solar cell (μmMSC) was developed for low-cost, flexible, and sustainable power generation. Unlike conventional systems, the proposed device utilizes a textile substrate, enabling mechanical flexibility and simplified fabrication. Microfluidic channels were patterned via screen printing using hydrophobic Ecoflex, and conductive electrodes were fabricated using PEDOT:PSS combined with Ag2O and carbon nanotubes (MWCNT/SWCNT). At the anode, Synechocystis sp., Bacillus subtilis, and Shewanella oneidensis MR-1 were vertically co-cultured to enhance synergistic bioelectrochemical activity, while Scenedesmus obliquus was employed as a microalgae-based biocathode. Under these conditions, the μmMSC achieved a maximum current density of 144 μA cm−2 and a peak power density of 17 μW cm−2. These results demonstrate that the proposed textile-based μmMSC provides a promising platform for flexible bio-solar energy systems, with potential for wearable applications, while offering improved sustainability and scalability compared to conventional rigid device. Full article
(This article belongs to the Special Issue Microfluidic Systems for Sustainable Energy)
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36 pages, 8798 KB  
Review
Advancing Functional Electrocatalysts for Hybrid Water Splitting: Strategies for Energy-Efficient Hydrogen Production
by Thirukumaran Periyasamy, Shakila Parveen Asrafali and Jaewoong Lee
Micromachines 2026, 17(5), 548; https://doi.org/10.3390/mi17050548 - 29 Apr 2026
Viewed by 212
Abstract
Electrocatalytic water splitting powered by renewable energy is a promising route for sustainable hydrogen production. Rather than developing separate catalysts for HER and OER, recent efforts focus on multifunctional electrocatalysts that can efficiently drive both reactions, simplifying system design and improving efficiency. A [...] Read more.
Electrocatalytic water splitting powered by renewable energy is a promising route for sustainable hydrogen production. Rather than developing separate catalysts for HER and OER, recent efforts focus on multifunctional electrocatalysts that can efficiently drive both reactions, simplifying system design and improving efficiency. A major limitation of conventional water splitting is the high overpotential and low-value oxygen production in OER. To overcome this, hybrid water splitting replaces OER with more valuable oxidation reactions, such as pollutant degradation or organic upgrading, enhancing overall energy and economic efficiency. This review covers the fundamentals of water splitting and highlights key physicochemical techniques for probing electrocatalyst activity, particularly structural reconstruction under operating conditions. It evaluates noble-metal, nonprecious-metal, and metal-free nanocarbon catalysts in both acidic and alkaline media, with emphasis on their roles in alternative anodic reactions. Finally, it outlines current challenges and future directions for developing efficient, durable, and sustainable electrocatalysts for advanced hydrogen production systems. Full article
(This article belongs to the Section C:Chemistry)
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33 pages, 5264 KB  
Article
Numerical Investigations on Heat Transfer Characteristics of Mono and Hybrid Nanofluids Using Microchannel Cooling for 21700 Batteries in Electric Vehicles
by Tai Duc Le and Moo-Yeon Lee
Micromachines 2026, 17(4), 497; https://doi.org/10.3390/mi17040497 - 18 Apr 2026
Viewed by 435
Abstract
Efficient thermal management is critical for maintaining the safety, durability, and performance of lithium-ion batteries used in electric vehicles (EVs). In this study, a comprehensive numerical investigation is conducted to evaluate the heat transfer characteristics of mono- and hybrid-nanofluids in a microchannel-cooled lithium-ion [...] Read more.
Efficient thermal management is critical for maintaining the safety, durability, and performance of lithium-ion batteries used in electric vehicles (EVs). In this study, a comprehensive numerical investigation is conducted to evaluate the heat transfer characteristics of mono- and hybrid-nanofluids in a microchannel-cooled lithium-ion battery module. A three-dimensional computational model of a 5S7P battery module composed of cylindrical 21700 cells is developed. Battery heat generation during 3C high discharge rate operation is predicted using the Newman-Tiedemann-Gu-Kim (NTGK) electrochemical model, while coolant flow and heat transfer are simulated using the governing conservation equations for mass, momentum, and energy. The cooling system consists of six liquid-cooling plates with circular microchannels. The performance of water-glycol (50/50) coolant is compared with several mono nanofluids of Al2O3 and Cu, and hybrid nanofluids of Al2O3-Cu, Al2O3-MWCNT, Al2O3-Graphene, Cu-MWCNT, and Cu-Graphene across multiple coolant flow rates from 1–5 LPM. The results demonstrate that nanofluids significantly enhance convective heat transfer and reduce battery temperature compared with the conventional water-glycol coolant. Among the investigated coolants, the Al2O3-Cu hybrid nanofluid (0.45–0.45%) operating at 1 LPM achieves the best overall thermo-hydraulic performance with a performance evaluation criterion (PEC) of 1.065. Further analysis of nanoparticle composition ratios shows that a Cu-dominant hybrid mixture (Al2O3-Cu: 0.27–0.63%) slightly improves the PEC to 1.0657, indicating marginally superior cooling performance. The findings highlight the potential of hybrid nanofluids as advanced coolants for microchannel-based battery thermal management systems in EVs, particularly under moderate coolant flow conditions. Full article
(This article belongs to the Special Issue Microfluidic Systems for Sustainable Energy)
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23 pages, 7891 KB  
Article
Synergistic Enhancement of WO3@Co3O4 Layered Supercapacitors via PAA-Directed Electrodeposition: A Comparative Polymer Strategy with HMTA Surfactant
by Pritam J. Morankar and Chan-Wook Jeon
Micromachines 2026, 17(4), 407; https://doi.org/10.3390/mi17040407 - 26 Mar 2026
Viewed by 497
Abstract
In this study, a novel layered WO3@Co3O4 composite electrode was synthesized via a controlled electrodeposition method employing different surfactants to finely tune its nanostructure. The incorporation of polyacrylic acid (PAA) surfactant yielded an optimized P-W@Co electrode with a [...] Read more.
In this study, a novel layered WO3@Co3O4 composite electrode was synthesized via a controlled electrodeposition method employing different surfactants to finely tune its nanostructure. The incorporation of polyacrylic acid (PAA) surfactant yielded an optimized P-W@Co electrode with a hierarchical porous morphology and reduced crystallite size, markedly enhancing electroactive site exposure and electron transport. Structural analyses confirmed the amorphous nature of WO3 and crystalline spinel Co3O4 phases forming an integrated composite architecture. Electrochemical characterizations in a three-electrode system revealed that the P-W@Co electrode exhibited superior pseudocapacitive behavior, with an areal capacitance of 11.70 F/cm2 at 20 mA/cm2 and excellent rate capability, retaining 80% capacitance at 40 mA/cm2. Kinetic studies demonstrated enhanced diffusion-controlled charge storage attributed to improved ion accessibility and charge transfer kinetics. To evaluate practical feasibility, asymmetric supercapacitor devices incorporating P-W@Co as the positive electrode coupled with activated carbon as the negative electrode were fabricated. This device showcased a widened operational voltage (1.5 V), outstanding areal capacitance (211 mF/cm2), and energy density (0.066 mWh/cm2). Importantly, the device exhibited exceptional cycling stability, retaining 81.8% capacitance after 7000 cycles. This work signifies a major advancement in surfactant-mediated design of WO3@Co3O4 layered electrodes for scalable, high-performance supercapacitor applications, combining structural stability, enhanced conductivity, and multifaceted charge storage mechanisms. Full article
(This article belongs to the Special Issue Microdevices and Electrode Materials for Electrochemical Applications)
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19 pages, 14641 KB  
Article
Moisture-Controlled Electrolyte Engineering Enables Durable Calcium-Ion Batteries
by Yeon Jwoong Kim, Tejaswi Tanaji Salunkhe and Il Tae Kim
Micromachines 2026, 17(4), 390; https://doi.org/10.3390/mi17040390 - 24 Mar 2026
Viewed by 506
Abstract
Calcium-ion batteries (CIBs) offer several advantages. CIBs are viable alternatives to lithium-based battery systems owing to the natural abundance, low cost, and high volumetric capacity of calcium. However, their development has been severely constrained by electrolyte instability and water sensitivity. We conducted a [...] Read more.
Calcium-ion batteries (CIBs) offer several advantages. CIBs are viable alternatives to lithium-based battery systems owing to the natural abundance, low cost, and high volumetric capacity of calcium. However, their development has been severely constrained by electrolyte instability and water sensitivity. We conducted a systematic examination of Ca(ClO4)2 and Ca(PF6)2 electrolytes, focusing on low-cost salt production, solvent selection, and stringent dehydration procedures. Acetonitrile (ACN) was the ideal solvent for high salt solubility and reversible Ca2+ electrochemistry, while carbonate solvents failed rapidly. We found that even a small amount of moisture in the electrolyte significantly affected the electrochemical performance. This study improved the dehydration process by using 3 Å molecular sieve (MS3A) and vacuum drying to reduce moisture to ppm levels, stabilizing the electrolyte. Prussian blue (PB) half cells exhibited reversible capacities of up to ≈95 mAh g−1, whereas PB-hard carbon full cells utilizing dried Ca(ClO4)2 showed stable cycling over 240 cycles with a Coulombic efficiency of ≈99% and capacity loss of only ≈17%. This study establishes a moisture-controlled electrolyte as a critical enabler for practical CIBs. Full article
(This article belongs to the Special Issue Microdevices and Electrode Materials for Electrochemical Applications)
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12 pages, 2256 KB  
Article
CO2 Sensing Characteristics of 2H-MoS2-Coated D-Shaped Optical Fiber Sensors
by Han-Mam Kang, Hyung-il Jang, Tae-Jung Ahn and Min-Ki Kwon
Micromachines 2026, 17(3), 341; https://doi.org/10.3390/mi17030341 - 11 Mar 2026
Viewed by 448
Abstract
In this study, a highly crystalline 2H (hexagonal)-phase MoS2 sensing layer with a precisely controlled crystal structure was realized through a combination of DC sputtering and sulfurization annealing processes, and subsequently integrated with a D-shaped optical fiber to develop a highly sensitive [...] Read more.
In this study, a highly crystalline 2H (hexagonal)-phase MoS2 sensing layer with a precisely controlled crystal structure was realized through a combination of DC sputtering and sulfurization annealing processes, and subsequently integrated with a D-shaped optical fiber to develop a highly sensitive carbon dioxide (CO2) sensor. Conventionally sputtered MoS2 thin films often suffer from the presence of unstable metallic 1T (tetragonal) phases and a high density of sulfur vacancies, which significantly degrade sensor reversibility and long-term stability. Here, high-temperature annealing under a sulfur-rich atmosphere was employed to induce a complete phase transition from the metastable 1T phase to the stable semiconducting 2H phase, while simultaneously healing sulfur vacancies. Enhanced crystallinity was confirmed by Raman spectroscopy. The fabricated sensor exhibited excellent linearity (R2 > 0.99) and markedly improved repeatability over a CO2 concentration range of 1000–10,000 ppm. This significant performance enhancement is attributed to reversible charge transfer induced by sulfur vacancy passivation, which modulates the complex refractive index of the MoS2 layer and optimizes optical interaction with the evanescent field of the D-shaped fiber. The phase engineering and defect-healing strategy presented in this work effectively addresses the drift issues commonly observed in conventional electrical gas sensors and provides a crucial pathway toward the realization of high-performance optical gas sensors. Full article
(This article belongs to the Special Issue Gas Sensors and Electronic Noses)
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16 pages, 1922 KB  
Article
A Novel 3D-Printed Flow Cell Design for In Operando Disposable Printed Electrode Replacement: Improving Continuous Methylene Blue Determination
by Željka Boček, Elizabeta Forjan, Andrej Molnar, Marijan-Pere Marković, Domagoj Vrsaljko and Petar Kassal
Micromachines 2026, 17(3), 325; https://doi.org/10.3390/mi17030325 - 5 Mar 2026
Viewed by 573
Abstract
Using disposable screen-printed electrodes faces major challenges when attempting to monitor a continuous process, especially in systems where there is pronounced adsorption, fouling, degradation, or in cases of irreversible electrochemical reactions. Methylene Blue (MB) exhibits some therapeutic properties and is commonly used as [...] Read more.
Using disposable screen-printed electrodes faces major challenges when attempting to monitor a continuous process, especially in systems where there is pronounced adsorption, fouling, degradation, or in cases of irreversible electrochemical reactions. Methylene Blue (MB) exhibits some therapeutic properties and is commonly used as a redox reporter in DNA sensors, but is also considered a toxic pollutant in aquatic systems. MB demonstrates strong adsorption to carbon materials, which prevents its electroanalytical determination in multiple measurements with a single electrode. Our work details direct electrochemical determination of MB with only the native carbon screen-printed working electrode as sensing material and optimization of the analytical method. In batch mode, we significantly improved sensitivity and interelectrode reproducibility by introducing a prepolarization step, but successive measurements in lower concentrations were not feasible due to strong adsorption. A fully customizable, modular flow cell was 3D printed to allow in operando replacement of the planar screen-printed three-electrode system after measurement during continuous flow. As confirmed by mechanical properties testing, the rigid polyacrylate upper section of the flow cell provides structural stability, combined with a flexible TPU lower section which enables effortless sensor hot swapping and effective sealing during flow. With an optimized hot swapping flow detection method, MB was detected via square wave voltammetry with a sensitivity of 65.59 µA/µM and a calculated LOD of 7.75 nM, which outperforms similar systems from the literature. We envisage this approach can be integrated into low-cost continuous environmental monitoring systems or in-line quality control, especially in flow chemistry synthesis. Full article
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20 pages, 4253 KB  
Article
Construction of Highly Active Interfaces on Screen-Printed Carbon Electrodes via Controllable Electrochemical Exfoliation for High-Performance Flexible Enzyme-Free Glucose Sensing
by Wenjing Xue, Ziyan Chen, Xiao Peng, Haocheng Yin, Yimeng Zhang and Yuming Zhang
Micromachines 2026, 17(2), 251; https://doi.org/10.3390/mi17020251 - 16 Feb 2026
Viewed by 494
Abstract
Enzyme-free flexible glucose sensors hold great promise in the field of wearable health monitoring. However, their performance is limited by the balance between the catalytic interface activity and stability. This paper reports a strategy for interface gradient roughening of screen-printed carbon electrodes (SPCE) [...] Read more.
Enzyme-free flexible glucose sensors hold great promise in the field of wearable health monitoring. However, their performance is limited by the balance between the catalytic interface activity and stability. This paper reports a strategy for interface gradient roughening of screen-printed carbon electrodes (SPCE) via controllable electrochemical exfoliation (EE). It systematically reveals the inherent relationships among the degree of EE treatment, electrode morphology, surface chemistry, and electrochemical performance. On this basis, the deposition of gold nanoparticles (AuNPs) with high density and uniform distribution is achieved, and a high-performance flexible enzyme-free glucose sensor is constructed. The study finds that EE treatment can significantly increase the true surface area of the electrode and introduce abundant oxygen-containing functional groups, thus effectively reducing the charge transfer resistance. Nevertheless, excessive exfoliation leads to the degradation of the conductive network, indicating the existence of a critical “performance window”. The EE-SPCE optimized with 150 cycles has both a high active area and good electrical conductivity, providing an ideal deposition substrate for AuNPs, increasing their distribution density by approximately 158% and reducing the average particle size to 125 nm. The fabricated AuNPs/EE-SPCE sensor exhibits excellent performance in glucose detection: it has a high sensitivity of 550.766 μA·mM−1·cm−2 in the range of 0.1–3 mM, a detection limit of 0.0998 mM, a wide linear range, excellent selectivity, long-term stability, and good mechanical flexibility. This research not only develops an efficient and scalable method for constructing flexible sensing interfaces but also clarifies the trade-off relationship among “roughening–conductivity–catalytic performance” at the mechanistic level, providing an important theoretical basis and a general strategy for rationally designing high-performance flexible electrochemical devices. Full article
(This article belongs to the Special Issue Microdevices and Electrode Materials for Electrochemical Applications)
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20 pages, 6080 KB  
Article
CFD Simulation and Structural Optimization Analysis of Micromixing Processes in T-Shaped Microreactors
by Yongzhi Ning, Bo Wang, Runci Wang and Taihong Yan
Micromachines 2026, 17(2), 234; https://doi.org/10.3390/mi17020234 - 11 Feb 2026
Viewed by 529
Abstract
Microreactors offer remarkable advantages in intensifying mixing/mass transfer and hold promising prospects for industrial applications. In this study, T-shaped microreactors (TMRs) integrated with baffle, orifice-plate, and venturi structures (featuring different contraction angles) were designed. Based on the Villermaux–Dushman reaction system, three-dimensional computational fluid [...] Read more.
Microreactors offer remarkable advantages in intensifying mixing/mass transfer and hold promising prospects for industrial applications. In this study, T-shaped microreactors (TMRs) integrated with baffle, orifice-plate, and venturi structures (featuring different contraction angles) were designed. Based on the Villermaux–Dushman reaction system, three-dimensional computational fluid dynamics (CFD) models were established to simulate the fluid flow and mixing-reaction processes in these microreactors. The results demonstrate that peaks in velocity, turbulent kinetic energy, and turbulent dissipation rate consistently emerge in the confluence region of the two fluid streams. In the operating range of this study, the baffle configuration exhibits the highest micromixing performance but also induces the largest pressure drop, followed by the orifice-plate structure. Notably, the venturi structure not only enhances micromixing efficiency but also results in a minimal increase in pressure drop and eliminates flow dead zones. Specifically, the venturi structure with a 45° contraction angle achieves a balance between energy consumption and micromixing efficiency. Using the agglomeration model, the micromixing times of the microreactors with various structures were determined to range from 0.025 to 0.234 ms. Full article
(This article belongs to the Section C:Chemistry)
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18 pages, 4617 KB  
Article
Numerical and Experimental Investigation of Mixing Enhancement in a Zigzag Passive Micromixer with D-Shaped Obstacles
by Bingyang Yuan, Shuai Yuan and Hao Wang
Micromachines 2026, 17(2), 190; https://doi.org/10.3390/mi17020190 - 30 Jan 2026
Cited by 1 | Viewed by 659
Abstract
Micromixers are crucial for rapid and homogeneous mixing in lab-on-a-chip systems. This study presents a novel passive micromixer that synergistically combines a Zigzag channel with D-shaped obstacles to enhance mixing across a broad Reynolds number (Re) range of 0.1–50. The design leverages flow [...] Read more.
Micromixers are crucial for rapid and homogeneous mixing in lab-on-a-chip systems. This study presents a novel passive micromixer that synergistically combines a Zigzag channel with D-shaped obstacles to enhance mixing across a broad Reynolds number (Re) range of 0.1–50. The design leverages flow splitting, recombination, and the generation of localized high-velocity streams to effectively disrupt laminar flow. A comprehensive parametric study optimized key geometric parameters, including obstacle dimensions (b2, a2) and the number of mixing units (n). Results show that optimizing b2 to 500 μm and increasing a2 to 250 μm significantly enhances mixing efficiency. Mechanistic analysis reveals that centrifugal forces in the Zigzag channel work synergistically with obstacle-induced perturbations to stretch and fold the fluid interface, promoting transverse transport. The optimized mixer, fabricated and experimentally validated, achieves a high mixing index (>0.85) under all Re conditions. This work provides valuable design insights for developing efficient, compact micromixers for micro-total analysis systems. Full article
(This article belongs to the Section C:Chemistry)
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13 pages, 3168 KB  
Article
Fast Prototyping Ceramic Gas Flow Sensors for Harsh Operating Conditions
by Andrey Kasenko, Pavel Shchur, Ekaterina Anatolevna Drach, Ivan Borzunov, Vasily V. Egorov, Boris Prudnikov, Konstantin Oblov, Arthur Litvinov, Yuri Voronov and Nikolay Samotaev
Micromachines 2026, 17(2), 188; https://doi.org/10.3390/mi17020188 - 30 Jan 2026
Viewed by 1016
Abstract
The technology development for the mass ceramic gas flow sensor (CGFS) adopted for harsh operating conditions is presented. The main characteristic of this technology is its simplicity and affordability for mass fast prototyping of CGFS with a limited set of technological equipment. Special [...] Read more.
The technology development for the mass ceramic gas flow sensor (CGFS) adopted for harsh operating conditions is presented. The main characteristic of this technology is its simplicity and affordability for mass fast prototyping of CGFS with a limited set of technological equipment. Special attention is paid to the discussion of the technological and operational materials’ compatibility, flexibility, and speed of their processing to adapt the best mass flow sensor design option. The CGFS, designed and manufactured in just a few days, was tested in conditions close to the real ones and demonstrated the ability to measure gas flow in the range from 0.21 m/s to 1.25 m/s, with a constant power consumption of 152 mW@346 °C. Full article
(This article belongs to the Special Issue Gas Sensors and Electronic Noses)
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17 pages, 3206 KB  
Article
Effect of Channel Height on CO2-to-CH4 Reduction in Microchannel Electrocatalysis
by Zheng-Yan Lei, Nguyen Van Toan, Masaya Toda, Ioana Voiculescu and Takahito Ono
Micromachines 2026, 17(2), 148; https://doi.org/10.3390/mi17020148 - 23 Jan 2026
Viewed by 563
Abstract
Electrocatalytic CO2 reduction is a promising approach to mitigate rising atmospheric CO2 levels while converting CO2 into valuable products such as CH4. Conversion into other useful substances further expands its potential applications. However, the efficiency of the CO [...] Read more.
Electrocatalytic CO2 reduction is a promising approach to mitigate rising atmospheric CO2 levels while converting CO2 into valuable products such as CH4. Conversion into other useful substances further expands its potential applications. However, the efficiency of the CO2 reduction reaction (CO2RR) is strongly influenced by device geometry and CO2 mass transfer in the electrolyte. In this work, we present and evaluate microchannel electrocatalytic devices consisting of a porous Cu cathode and a Pt anode, fabricated via metal-assisted chemical etching (MACE). The porous surfaces generated through MACE enhanced reaction activity. To study the impact of the distance between electrodes, several devices with different channel heights were fabricated and tested. The device with the highest CH4 selectivity had a narrow inter-electrode gap of 50 μm and achieved a Faradaic efficiency of 56 ± 11% at an applied potential of −5 V versus an Ag/AgCl reference electrode. This efficiency was considerably higher than that of the device with larger inter-electrode gaps (300 and 480 μm). This reduced efficiency in the larger channel was attributed to limited CO2 availability at the cathode surface. Bubble visualization experiments further demonstrated that the electrolyte flow rate had a strong impact on supplied CO2 bubble morphology and mass transfer. At a flow rate of 0.75 mL/min, smaller CO2 bubbles were formed, increasing the gas–liquid interfacial area and thereby enhancing CO2 dissolution into the electrolyte. These results underline the critical role of electrode gap design and bubble dynamics in optimizing microchannel electrocatalytic devices for efficient CO2RR. Full article
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