Topology optimization of multichannel step emulsification droplet generators
摘要
Microfluidics is pivotal in producing monodisperse microemulsions and microspheres. However, lower output efficiency hinders its practical application. Although multichannel droplet generators offer a promising solution for increased productivity, their design is inherently complex, and achieving uniform fluid distribution across channels is a significant challenge. Hence, in this paper, a novel rapid-design approach is introduced for multichannel droplet generators and employs topology optimization to enhance the structure, leading to significant improvements in droplet generation efficiency and uniformity. It can automatically generate a multichannel droplet generator structure that meets experimental conditions within five hours and is compatible with 3D printing technology. By employing topology optimization, the design achieves an average inter-channel flow rate variation of less than 1%, even with 81 channels, while reducing the inlet-outlet pressure drop by 19.75% compared to unoptimized configurations. The optimized device can produce both water-in-oil (W/O) and oil-in-water (O/W) droplets at a maximum throughput of 65 mL·min⁻¹, with a coefficient of variation (CV) below 5%, ensuring excellent monodispersity. Moreover, the topology optimization approach provides a comprehensive analytical framework for droplet generators with a matrix of microchannels, thereby facilitating rational design and scalability.
Graphical abstract