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Droplet-based microfluidic systems require a precise control of droplet physical properties; hence, measuring the morphological properties of droplets is critical to obtain high sensitivity analysis. The ability to perform such measurements in real-time is another demand which has not been addressed yet. In this study, we used coplanar electrodes configured in the differential measurement mode for impedimetric measurement of size and velocity. To obtain the size of the droplets, detailed 3D finite element simulations of the system were performed. The interaction of the non-uniform electric field and the droplet was investigated. Electrode geometry optimization steps were described and design guideline rules were laid out. User-friendly software was developed for real-time observation of droplet length and velocity together with in situ statistical analysis results. A comparison between impedimetric and optical measurement tools is given. Finally, to illustrate the benefit of having real-time analysis, iDM was used to synthesize particles with a predefined monodispersity limit and to study the response times of syringe pump and pressure pump driven droplet generation devices. This analysis allows one to evaluate the 'warm-up' time for a droplet generator system, after which droplets reach the desired steady-state size required by the application of interest. [ABSTRACT FROM AUTHOR]

[Display omitted] • New forms of particle behaviour were presented for colloidal solutions in microchannels. • The novel patterns are hypothesized to be due to nonuniformity of electric double layer and particle rotation due to shear flow. • The observations were done using Newtonian aqueous solutions and are applicable to a wide range of solutions. • These results challenge the Saffman-like slip velocity induced lift mechanisms used to explain the cross-stream particle migration. The lateral migration of colloidal particles inside a microfluidic channel has gained attention due to being both fundamentally intriguing and applicable for particle separation, such as cancer cell isolation or extracellular vesicle purification. Applying an external electric field combined with a pressure-driven flow induces such lateral migrations. In this study, new modes of lateral particle migration have been found by experimentally investigating 6 µm particles in the co-presence of electric field and pressure-driven flow. The experiments revealed the importance of the relative strengths of electric field and pressure gradient in determining particle lateral positioning. We hypothesize that the nonuniformity of the polarization caused by the external electric field and the rotation of the particle due to the background pressure-driven flow result in these modes of transverse migration. These new migration patterns are further utilized to perform microparticle separation and, more importantly, present a novel separation modality. [ABSTRACT FROM AUTHOR]