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The interaction of surface acoustic waves (SAWs) with liquids enables the production of aerosols with adjustable droplet sizes in the micrometer range expelled from a very compact source. Understanding the nonlinear acousto-hydrodynamics of SAWs with a regulated micro-scale liquid film is essential for acousto-microfluidics platforms, particularly aerosol generators. In this study, we demonstrate the presence of micro-cavitation in a MHz-frequency SAW aerosol generation platform, which is touted as a leap in aerosol technology with versatile application fields including biomolecule inhalation therapy, micro-chromatography and spectroscopy, olfactory displays, and material deposition. Using analysis methods with high temporal and spatial resolution, we demonstrate that SAWs stabilize spatially arranged liquid micro-domes atop the generator's surface. Our experiments show that these liquid domes become acoustic resonators with highly fluctuating pressure amplitudes that can even nucleate cavitation bubbles, as supported by analytical modeling. The observed fragmentation of liquid domes indicates the participation of three droplet generation mechanisms, including cavitation and capillary-wave instabilities. During aerosol generation, the cavitation bubbles contribute to the ejection of droplets from the liquid domes and also explain observed microstructural damage patterns on the chip surface eventually caused by cavitation-based erosion.

Acoustic streaming (AS) is the steady time-averaged flow generated by acoustic field, which has been widely used in enhancing mixing and particle manipulation. Current researches on acoustic streaming mainly focus on Newtonian fluids, while many biological and chemical solutions exhibit non-Newtonian properties. The acoustic streaming in viscoelastic fluids has been studied experimentally for the first time in this paper. We found that the addition of polyethylene oxide (PEO) polymer to the Newtonian fluid significantly altered the flow characteristics in the microchannel. The resulting acousto-elastic flow showed two modes: positive mode and negative mode. Specifically, the viscoelastic fluids under acousto-elastic flow exhibit mixing hysteresis features at low flow rates, and degeneration of flow pattern at high flow rates. Through quantitative analysis, the degeneration of flow pattern is further summarized as time fluctuation and spatial disturbance range reduction. The positive mode in acousto-elastic flow can be used for the mixing enhancement of viscoelastic fluids in the micromixer, while the negative mode provides a potential method for particle/cell manipulation in viscoelastic body fluids such as saliva by suppressing unstable flow.

In droplet-based microfluidic platforms, precise separation of microscale droplets of different chemical composition is increasingly necessary for high-throughput combinatorial chemistry in drug discovery and screening assays. A variety of droplet sorting methods have been proposed, in which droplets of the same kind are translocated. However, there has been relatively less effort in developing techniques to separate the uniform-sized droplets of different chemical composition. Most of the previous droplet sorting or separation techniques either rely on the droplet size for the separation marker or adopt on-demand application of a force field for the droplet sorting or separation. The existing droplet microfluidic separation techniques based on the in-droplet chemical composition are still in infancy because of the technical difficulties. In this study, we propose an acoustofluidic method to simultaneously separate microscale droplets of the same volume and dissimilar acoustic impedance using ultrasonic surface acoustic wave (SAW)-induced acoustic radiation force (ARF). For extensive investigation on the SAW-induced ARF acting on both cylindrical and spherical droplets, we first performed a set of the droplet sorting experiments under varying conditions of acoustic impedance of the dispersed phase fluid, droplet velocity, and wave amplitude. Moreover, for elucidation of the underlying physics, a new dimensionless number ARD was introduced, which was defined as the ratio of the ARF to the drag force acting on the droplets. The experimental results were comparatively analyzed by using a ray acoustics approach and found to be in good agreement with the theoretical estimation. Based on the findings, we successfully demonstrated the simultaneous separation of uniform-sized droplets of the different acoustic impedance under continuous application of the acoustic field in a label-free and detection-free manner. Insomuch as on-chip, precise separation of multiple kinds of droplets is critical in many droplet microfluidic applications, the proposed acoustofluidic approach will provide new prospects for microscale droplet separation.

Surface acoustic wave (SAW)-based acoustofluidics has shown significant promise to manipulate micro/nanoscale objects for biomedical applications, e.g. cell separation, enrichment, and sorting. A majority of the acoustofluidic devices utilize microchannels with rectangular cross-section where the acoustic waves propagate in the direction perpendicular to the sample flow. A region with weak acoustic wave intensity, termed microchannel anechoic corner (MAC), is formed inside a rectangular microchannel of the acoustofluidic devices where the ultrasonic waves refract into the fluid at the Rayleigh angle with respect to the normal to the substrate. Due to the absence of a strong acoustic field within the MAC, the microparticles flowing adjacent to the microchannel wall remain unaffected by a direct SAW-induced acoustic radiation force (ARF). Moreover, an acoustic streaming flow (ASF) vortex produced within the MAC pulls the particles further into the corner and away from the direct ARF influence. Therefore, a residue of particles continues to flow past the SAWs without intended deflection, causing a decrease in microparticle manipulation efficiency. In this work, we introduce a cross-type acoustofluidic device composed of a half-circular microchannel, fabricated through a thermal reflow of a positive photoresist mold, to overcome the limitations associated with rectangular microchannels, prone to the MAC formation. We investigated the effects of different microchannel cross-sectional shapes with varying contact angles on the microparticle deflection in a continuous flow and found three distinct regimes of particle deflection. By systematically removing the MAC out of the microchannel cross-section, we achieved residue-free acoustofluidic microparticle manipulation via SAW-induced ARF inside a half-circular microchannel. The proposed method was applied to efficient fluorescent coating of the microparticles in a size-selective manner without any residue particles left undeflected in the MAC.

Traditional cell/particle isolation methods are time-consuming and expensive and can lead to morphology disruptions due to high induced shear stress. To address these problems, novel lab-on-a-chip-based purification methods have been employed. Among various methods introduced for the separation and purification of cells and synthetics particles, acoustofluidics has been one of the most effective methods. Unlike traditional separation techniques carried out in clinical laboratories based on chemical properties, the acoustofluidic process relies on the physical properties of the sample. Using acoustofluidics, manipulating cells and particles can be achieved in a label-free, contact-free, and highly biocompatible manner. To optimize the functionality of the platform, the numerical study should be taken into account before conducting experimental tests to save time and reduce fabrication expenses. Most current numerical studies have only considered one-dimensional harmonic standing waves to simulate the acoustic pressure distribution. However, one-dimensional simulations cannot calculate the actual acoustic pressure distribution inside the microchannel due to its limitation in considering longitudinal waves. To address this limitation, a two-dimensional numerical simulation was conducted in this study. Our numerical simulation investigates the effects of the platform geometrical and operational conditions on the separation efficiency. Next, the optimal values are tested in an experimental setting to validate these optimal parameters and conditions. This work provides a guideline for future acoustofluidic chip designs with a high degree of reproducibility and efficiency.

A true non-intrusive 3D Micro-Acoustic Trap for a controlled monolayer assembly of microparticles in aqueous environment. Modulation of acoustic pressure generated by an acoustic lens can assist in particle manipulation and formation of a monolayer of polystyrene beads suspended in aqueous media. The same experimental model can also be used for manipulating and probing live cells. • Micro-Acoustic Trap for controlled assembly of microparticles as a monolayer suspended in aqueous media. • A suspended 2D monolayer of polystyrene beads with hexagonal close pack lattice with high density of particles. • Multilayered monolayer arrangement of microparticles in 3D. • Acoustically controlled mobility and segregation of live cell. Acoustic tweezers facilitate the manipulation of objects using sound waves. With the current state of the technology one can only control mobility for a single or few microparticles. This article presents a state of the art system where an Acoustic Lens was used for developing a Micro-Acoustic Trap for microparticle assembly in 3D. The model particles, 2 µm diameter polystyrene beads in suspension, were driven via acoustic pressure to form a monolayer at wavelength-defined distances above the substrate defined by the focal point of an Acoustic Lens The transducer was driven at 89 MHz, mixed with 100 ms pulses at a repetition rate of 2 Hz. Beyond a threshold drive amplitude sufficient to overcome Brownian motion, this led to 2D assembly of the microparticles into close-packed rafts >80 µm across (∼5 wavelengths of the carrier wave and >40 particles across). This methodology was further extended to manipulation of live Dictyostelium discoideum amoebae. This approach therefore offers maneuverability in controlling or assembling micrometer-scale objects using continuous or pulsed focused acoustic radiation pressure. [ABSTRACT FROM AUTHOR]

• Continuous particle synthesis in a dual-frequency ultrasound microreactor. • Novel application mode of switching between low- and high-frequency ultrasound. • Synergistic effects of low-frequency cavitation and high-frequency acoustophoresis. • Dual-frequency ultrasound results in particles with a narrow size distribution. • High ultrasound energy efficiency and temperature control is achieved. Ultrasound (US) is a promising method to address clogging and mixing issues in microreactors (MR). So far, low frequency US (LFUS), pulsed LFUS and high frequency US (HFUS) have been used independently in MR for particle synthesis to achieve narrow particle size distributions (PSD). In this work, we critically assess the advantages and disadvantages of each US application method for the case study of calcium carbonate synthesis in an ultrasonic microreactor (USMR) setup operating at both LFUS (61.7 kHz, 8 W) and HFUS (1.24 MHz, 1.6 W). Furthermore, we have developed a novel approach to switch between LFUS and HFUS in an alternating manner, allowing us to quantify the synergistic effect of performing particle synthesis under two different US conditions. The reactor was fabricated by gluing a piezoelectric plate transducer to a silicon microfluidic chip. The results show that independently applying HFUS and LFUS produces a narrower PSD compared to silent conditions. However, at lower flow rates HFUS leads to agglomerate formation, while the reaction conversion is not enhanced due to weak mixing effects. LFUS on the other hand eliminates particle agglomerates and increases the conversion due to the strong cavitation effect. However, the required larger power input leads to a steep temperature rise in the reactor and the risk of reactor damage for long-term operation. While pulsed LFUS reduces the temperature rise, this application mode leads again to the formation of particle agglomerates, especially at low LFUS percentage. The proposed application mode of switching between LFUS and HFUS is proven to combine the advantages of both LFUS and HFUS, and results in particles with a unimodal narrow PSD (one order of magnitude reduction in the average size and span compared to silent conditions) and negligible rise of the reactor temperature. [ABSTRACT FROM AUTHOR]