Search Results (82)

The ultra-precision machining of micro-optics from low glass transition temperature (T_g) hydrophobic polymers is frequently compromised by thermal instability and kinematic constraints imposed by on-axis turning. To address these challenges, this study presents a novel clamping–cooling system engineered for the off-axis diamond turning of low-T_g polymers. The design integrates vacuum clamping for workpiece stabilization with an embedded microchannel network for efficient thermal management. Strategic material selection effectively balances thermal insulation with mechanical stability. Performance evaluations demonstrated robust thermal regulation: lens blank surface temperatures stabilized at 6 °C during stationary testing, and the system was able to drop below 0 °C under maximum cooling targets. This strict thermal control enabled achieving nanometer surface roughness. Ultimately, this modular system facilitates the scalable, simultaneous production of high-quality, polishing-free intraocular lenses (IOLs), advancing manufacturing capabilities for complex precision optics. Full article

This work analyzes the non-Newtonian electromagnetohydrodynamic (EMHD) flow in an irregular circular porous microchannel while incorporating the consequences of surface charge-dependent slip boundary conditions. The Jeffrey fluid is employed to examine the non-Newtonian behavior, such as elasticity. The boundary walls of the channel are considered in the form of periodic sinusoidal wave function. The mathematical formulation is developed using the momentum equation, modified Darcy’s law, the continuity equation, and Ohm’s law. The perturbation method is used to derive the solutions up to second-order approximation. The analytical expression for the velocity field and volumetric flow rate are explicitly presented. At the zeroth-order, a nonhomogeneous partial differential equation is solved, and the solutions are presented in terms of Bessel functions. The first-order problem defined by a homogeneous partial differential equation is solved using the method of separation of variables. At the second-order, a homogeneous partial differential equation is obtained, and the solution form is prescribed by the boundary conditions, consisting of a radially varying mean component and a second-harmonic angular contribution. Two- and three-dimensional plots are used to analyze and discuss the impacts of key parameters, namely the Reynolds, Darcy, and Hartmann numbers, channel corrugation amplitude and wave number, surface charge density, and the relaxation and retardation times on the velocity field and flow rate. It is found that elastic memory causes a proportional growth between the flow rate and the relaxation time, emphasizing the consequences of surface charge application in conjunction with corrugations. Conversely, maintaining a short retardation time mitigates changes in wave amplitude and surface charge. While prolonging it lessens the flow rate and diminishes corrugations and surface charge effects. The Darcy number dampens the velocity and the flow rate, while its enhancement reduces the impact of surface charge density and corrugations amplitude. For high Reynolds number, a ring phenomenon emerges which is attenuated by increased Darcy number, preventing the formation of trapped boluses close to the border. Ignoring surface charge amplifies the flow rate while its consideration diminishes the latter with reinforced impacts of surface charge and wall corrugations at higher Reynolds number. Full article

Microfluidics provides precise control of microscale fluid transport and has become central to biomedical, pharmaceutical, and industrial technologies. However, conventional fabrication methods such as photolithography and soft lithography require cleanroom facilities, use costly materials, and offer limited capability for constructing complex or multi-material architectures. This review highlights emerging manufacturing strategies, focusing on polymer-based micro-milling as an accessible and cost-effective alternative for microfluidic device production. Advances in micro-milling now enable the fabrication of microchannels and functional features with improved dimensional accuracy and surface quality, while additive manufacturing offers complementary rapid prototyping and design flexibility. Micro-milling is particularly promising for rapid prototyping of polymeric biosensor chips designed for point-of-care diagnostics. The technique supports diverse materials and eliminates reliance on cleanroom processing. Critical parameters, including tool geometry, spindle speed, and feeding rate, strongly influence fidelity and surface roughness, which directly affect biosensor sensitivity. Despite its advantages, challenges such as tool wear, burr formation, and limits on minimum feature size continue to hinder reproducibility. Recent progress in toolpath optimization, hybrid additive–subtractive methods, and real-time process monitoring shows the potential to overcome these barriers. Overall, micro-milling offers a scalable and economical route for fabricating accessible microfluidic and biosensing platforms, with future work needed to standardize processes and improve integration with surface functionalization methods. Full article

Aluminum alloy surface microstructures possess functional characteristics such as hydrophilicity/hydrophobicity and anti-icing and have important applications in fields such as aerospace and power systems. In order to improve the filling quality of the microstructure and verify the anti-icing property of the microstructure, this work develops a scheme for achieving large-area hot embossing of anti-icing functional microstructures based on a multi-arc ion-plating mold. Compared with conventional steel, the hardness of the PVD-coated steel increases by 44.7%, the friction coefficient decreases by 66.2%, and the wear resistance is significantly enhanced. The PVD-coated punch-assisted embossing could significantly improve filling properties. While the embossing temperature is 300 °C, the PVD-coated punch-assisted embossing can ensure the complete filling of the micro-array channels. In contrast, under-filling defects occur in conventional hot embossing. Then, a large-area micro-channel specimen of 100 cm² was precisely formed without warping, and the average surface roughness Ra was better than 0.8 µm. The maximum freezing fraction of the micro-array channel was reduced by about 53.2% compared with the planar, and the complete freezing time was delayed by 193.3%. The main reason is that the air layer trapped by the hydrophobic structures hinders heat loss at the solid–liquid interface. Full article

The role of wall roughness in heat and mass transfer for fully developed viscous flows in square microchannels is investigated here. Since the roughness, which is the key geometrical feature to be investigated, introduces high velocity gradients at the wall, the effect of the viscous dissipation is considered. A fully developed flow in the forced convection regime is assumed. This assumption allows the two-dimensional treatment of the problem; thus, the velocity and temperature fields are simulated on the microchannel cross-section. The boundary roughness is modeled by randomly throwing points around the nominal square cross-section perimeter and by connecting those points to generate a simple polygon. This modification of the nominal square shape of the cross-section influences the velocity and temperature fields, which are computed by employing a finite element method solver. The heat and mass transfer is studied by calculating the Nusselt and the Poiseuille numbers as a function of roughness amplitude at the boundary. Each Nusselt and Poiseuille number is obtained by employing an averaging procedure over a sample of a thousand cases. Full article

The present study investigates passive microdroplet generation in a T-junction microchannel using microscopic observations, microscale particle image velocimetry (Micro-PIV) visualization, and lattice Boltzmann simulations. The key flow regimes, i.e., dripping, threading, and parallel flow, are characterized by analyzing the balance between hydrodynamic forces and surface tension, revealing the critical role of the flow rate ratio of the continuous to dispersed fluids in regime transitions. Micro-PIV visualizes velocity fields and vortex structures during droplet formation, while a lattice Boltzmann model with wetting boundary conditions captures interface deformation and flow dynamics, showing good agreement with experiments in the dripping and threading regimes but discrepancies in the parallel flow regime due to neglected surface roughness. The present experimental results highlight non-monotonic trends in the maximum head interface and breakup positions of the dispersed fluid under various flow rates, reflecting the competition between the squeezing and shearing forces of the continuous fluid and the hydrodynamic and surface tension forces of the dispersed fluid. Quantitative analysis shows that the droplet size increases with the flow rate of continuous fluid but decreases with the flow rate of dispersed fluid, while generation frequency rises monotonically with the flow rate of dispersed fluid. The dimensionless droplet length correlates with the flow rate ratio, enabling tunable control over droplet size and flow regimes. This work enhances understanding of T-junction microdroplet generation mechanisms, offering insights for applications in precision biology, material fabrication, and drug delivery. Full article

In recent years, the application of microfluidic devices has increased, and three-dimensional (3D) printers for fabricating microdevices could be considered a suitable technique but, in some cases, may confront some issues. The main issues include channel roughness values, print orientation due to the 3D printer’s setup, filament materials, nozzle specifications, and condition. This study aims to analyze the capillary-driven flow in microdevices produced by 3D printers. Therefore, four 3D printer-based microchannels were investigated, and the capillary-driven flow of five liquids with different viscosities and contact angles was evaluated experimentally. The experimental results were compared with theoretical calculations using the Lucas−Washburn equation, and the impact of the width, length, and closed and open microchannel on flow behaviors was explored. The experimental results showed that the peak velocity for open and closed microchannels decreases with the length. Moreover, there were differences in flow behavior between open and closed microchannels. For the former, the maximum average velocity appeared in the microchannel with a width of 400 μm, while for the latter, it was for a width of 1000 μm. In addition, the flow velocity decreased when the viscosity increased, regardless of microchannel width. The decrease was more pronounced for the lower-viscosity liquids (ethanol and water) and smaller for the higher-viscosity ones (coffee and olive oil). Finally, the advantages and challenges of 3D printer-based microdevices are presented. Full article

Microfluidic technology is an emerging interdisciplinary field that uses micropipes to handle or manipulate tiny fluids in chemistry, fluid physics, and biomedical engineering. As one of the rapid prototyping methods, the three-dimensional (3D) printing technique, which is rapid and cost-effective and has integrated molding characteristics, has become an important manufacturing technology for microfluidic chips. Polymethyl-methacrylate (PMMA), as an exceptional thermoplastic material, has found widespread application in the field of microfluidics. This paper presents a comprehensive process study on the fabrication of fused deposition modeling (FDM) 3D-printed PMMA microfluidic chips (chips), encompassing finite element numerical analysis studies, orthogonal process parameter optimization experiments, and the application of 3D-printed integrated microfluidic reactors in the reaction between copper ions and ammonium hydroxide. In this work, a thermal stress finite element model shows that the printing platform temperature was a significant printing parameter to prevent warping and delamination in the 3D printing process. A single printing molding technique is employed to fabricate microfluidic chips with square cross-sectional dimensions reduced to 200 μm, and the microchannels exhibited no clogging or leakage. The orthogonal experimental method of 3D-printed PMMA microchannels was carried out, and the optimized printing parameter resulted in a reduction in the microchannel profile to Ra 1.077 μm. Finally, a set of chemical reaction experiments of copper ions and ammonium hydroxide are performed in a 3D-printed microreactor. Furthermore, a color data graph of copper hydroxide is obtained. This study provides a cheap and high-quality research method for future research in water quality detection and chemical engineering. Full article

Accurate separation in microfluidic devices is crucial for biomedical applications; however, enhancing their performance remains challenging due to computational and experimental constraints. This study aims to optimize microfluidic devices by systematically refining spiral microchannel configurations for the segregation of circulating tumor cells (CTCs) and red blood cells (RBCs) through detailed variable analysis and resource-efficient techniques. The spiral design was developed into six variations, considering loop numbers (2, 3, and 4), aspect ratios (2.333, 3.333, and 5), spiral radii (5, 6, and 7 mm), flow rates (1.5, 2, and 3 mL/min), surface roughness levels (0, 0.5, and 1 μm), and particle sizes (12, 18, and 24 μm). Simulations were conducted in COMSOL Multiphysics and evaluated using the Taguchi method to determine the optimal configuration, reducing the analysis set from 216 to 27 through an efficient experimental design approach. The results identified the optimal structure as having an aspect ratio of 3.333, four loops, a spiral radius of 6–7 mm, a flow rate of 3 mL/min, a surface roughness of 1 μm, and a particle diameter of 24 μm. Among the evaluated parameters, aspect ratio (61.2%) had the most significant impact, followed by the number of loops (13.9%) and flow rate (9.4%). The optimized design demonstrated high separation efficiency and purity, achieving 97.5% and 97.6%, respectively. The fabrication process involved 3D-printing the channel mold, followed by polydimethylsiloxane (PDMS) casting, validating the durability and scalability of the proposed design. This study integrates simulation and experimental results, providing a robust framework for developing next-generation microfluidic devices and advancing diagnostic and targeted therapeutic applications. Full article

In microfluidic chips, glass free-form microchannels have obvious advantages in thermochemical stability and biocompatibility compared to polymer-based channels, but they face challenges in processing morphology and quality. Hence, picosecond laser etching with galvanometer scanning is proposed to machine spiral microfluidic channels on a glass substrate. The objective is to disperse and sort microparticles from a glass microchip that is difficult to cut. First, the micropillar array and the spiral microchannel were designed to disperse and sort the particles in microchips, respectively; then, a scanning path with a scanning interval of 5 μm was designed according to the spot diameter in picosecond laser etching; next, the effects of laser power, scanning speed and accumulation times were experimentally investigated regarding the morphology of spiral microchannels; finally, the microfluidic flowing test with 5 μm and 10 μm microparticles was performed to analyze the dispersing and sorting performance. It was shown that reducing the laser power and accumulation times alongside increasing the scanning speed effectively reduced the channel depth and surface roughness. The channel surface roughness reached about 500 nm or less when the laser power was 9 W, the scanning speed was 1000 mm/s, and the cumulative number was 4. The etched micropillar array, with a width of 89 μm and an interval of 97 μm, was able to disperse the different microparticles into the spiral microchannel. Moreover, the spiral-structured channel, with an aspect ratio of 0.51, significantly influenced the velocity gradient distribution, particle focusing, and stratification. At flow rates of 300–600 μL/min, the microparticles produced stable focusing bands. Through the etched microchip, mixed 5 μm and 10 μm microparticles were sorted by stable laminar flow at flow rates of 400–500 μL/min. These findings contribute to the design and processing of high-performance glass microfluidic chips for dispersion and sorting. Full article

This review article highlights the critical impact of surface roughness in modifying the structure of two-phase flow within mini- and microchannels, particularly in processes such as boiling and condensation. Channel surface roughness enhances flow resistance, affects the distribution of vapor bubbles, and enhances heat transfer by providing additional nucleation sites. Several experiments have shown that while increased surface roughness enhances the efficiency of heat transfer, increased flow resistance may hurt system performance. This is so because too high a surface roughness negatively impacts flow resistance, a factor of importance in the optimization for a balance between heat transfer and flow resistance, especially in high-performance compact heat exchangers. Furthermore, the review identifies that higher-degree measurement and characterization techniques of the surface roughness are increasingly required, as traditional 2D parameters may not fully represent the actual physics of complex surface interactions in two-phase flow systems. Consequently, the article calls for further research that can examine the exact relationship between roughness, flow structure, and thermal performance with the aim of improving design strategies for future heat exchanger technologies. Full article

This study investigates the electroosmotic flow (EOF) of a two-layer Newtonian fluid system in a parallel plate microchannel with sinusoidal corrugated walls. The upper fluid is conducting, while the lower fluid is nonconducting. This analysis is performed under the Debye–Hückel approximation, utilizing perturbation expansion and the separation of variables. The potential distribution, velocity field, and the dependence of average velocity on roughness are derived. It is observed that the velocity distribution w(x, y), is significantly influenced by the phase difference θ between the corrugations on the upper and lower walls. The velocity w(x, y) decreases with an increase in the viscosity ratio μ_r of the bottom to top fluid, and w(x, y) is directly proportional to the dimensionless pressure gradient G and the zeta potential ratio ζ. The variation of the average velocity increment (roughness function) u_2m related to wall roughness tends to decrease with the increase of the corrugation wave number λ, the electrokinetic width K, the depth ratio h_r of the bottom to top fluid, the zeta potential ratio ζ and the dimensionless pressure gradient G; and increases with the increase of the viscosity ratio μ_r of the bottom to top fluid. Furthermore, the effect of u^I_2m is smaller than that of u^II_2m. Full article

This paper presents a novel centrifugal microfluidic approach (so-called lab-on-a-CD) for magnetic circulating tumor cell (CTC) separation from the other healthy cells according to their physical and acquired chemical properties. This study enhances the efficiency of CTC isolation, crucial for cancer diagnosis, prognosis, and therapy. CTCs are cells that break away from primary tumors and travel through the bloodstream; however, isolating CTCs from blood cells is difficult due to their low numbers and diverse characteristics. The proposed microfluidic device consists of two sections: a passive section that uses inertial force and bifurcation law to sort CTCs into different streamlines based on size and shape and an active section that uses magnetic forces along with Dean drag, inertial, and centrifugal forces to capture magnetized CTCs at the downstream of the microchannel. The authors designed, simulated, fabricated, and tested the device with cultured cancer cells and human cells. We also proposed a cost-effective method to mitigate the surface roughness and smooth surfaces created by micromachines and a unique pulsatile technique for flow control to improve separation efficiency. The possibility of a device with fewer layers to improve the leaks and alignment concerns was also demonstrated. The fabricated device could quickly handle a large volume of samples and achieve a high separation efficiency (93%) of CTCs at an optimal angular velocity. The paper shows the feasibility and potential of the proposed centrifugal microfluidic approach to satisfy the pumping, cell sorting, and separating functions for CTC separation. Full article

This study presents an automated methodology for evaluating micro-channels fabricated using a femtosecond laser on stainless steel substrates. We utilize 3D surface topography and metrological analyses to extract geometric features and detect fabrication defects. Standardized samples were analyzed using a light interferometer, and the resulting data were processed with Principal Component Analysis (PCA) and RANSAC algorithms to derive channel characteristics, such as depth, wall taper, and surface roughness. The proposed method identifies common defects, including bumps and V-defects, which can compromise the functionality of micro-channels. The effectiveness of the approach is validated by comparisons with commercial solutions. This automated procedure aims to enhance the reliability and precision of femtosecond laser micro-milling for industrial applications. The detected defects, combined with fabrication parameters, could be ingested in an AI-based process to optimize fabrication processes. Full article

Microfluidics is an important technology for the biomedical industry and is often utilised in our daily lives. Recent advances in micro-milling technology have allowed for rapid fabrication of smaller and more complex structures, at lower costs, making it a viable alternative to other fabrication methods. The microfluidic chip fabrication developed in this research is a step-by-step process with a self-contained wet milling chamber. Additionally, ethanol solvent bonding is used to allow microfluidic chips to be fully fabricated within approximately an hour. The effect of using this process is tested with quantitative contact profileometery data to determine the expected surface roughness in the microchannels. The effect of surface roughness on the controllability of microparticles is tested in functional microfluidic chips using image processing to calculate particle velocity. This process can produce high-quality channels when compared with similar studies in the literature and surface roughness affects the control of microparticles. Lastly, we discuss how the outcomes of this research can produce rapid and higher-quality microfluidic devices, leading to improvement in the research and development process within the fields of science that utilise microfluidic technology. Such as medicine, biology, chemistry, ecology, and aerospace. Full article