All-aqueous multiphase microfluidics

Immiscible aqueous phases, formed by dissolving incompatible solutes in water, have been used in green chemical synthesis, molecular extraction and mimicking of cellular cytoplasm. Recently, a microfluidic approach has been introduced to generate all-aqueous emulsions and jets based on these immiscible aqueous phases; due to their biocompatibility, these all-aqueous structures have shown great promises as templates for fabricating biomaterials. The physico-chemical nature of interfaces between two immiscible aqueous phases leads to unique interfacial properties, such as an ultra-low interfacial tension. Strategies to manipulate components and direct their assembly at these interfaces needs to be explored. In this paper, we review progress on the topic over the past few years, with a focus on the fabrication and stabilization of all-aqueous structures in a multiphase microfluidic platform. We also discuss future efforts needed from the perspectives of fluidic physics, materials engineering, and biology for fulfilling potential applications ranging from materials fabrication to biomedical engineering.     

A high-throughput cellulase screening system based on droplet microfluidics

A new ultra-high-throughput screening assay for the detection of cellulase activity was developed based on microfluidic sorting. Cellulase activity is detected using a series of coupled enzymes leading to the formation of a fluorescent product that can be detected on a chip. Using this method, we have achieved up to 300-fold enrichments of the active population of cells and greater than 90% purity after just one sorting round. In addition, we proved that we can sort the cellulase-expressing cells from mixtures containing less than 1% active cells.Cellulases are important enzymes with numerous applications across multiple industries, including biofuel, pulp, paper, textile and laundry, food, feed, brewing, and agriculture.¹ Most cellulases have low activity and stability, so improving these properties would have substantial impact on numerous industrial processes.Enzymatic properties can be improved by protein engineering² but the limiting step is the screening process. Classical screening uses microtiter plates (MTPs), where each well contains cells expressing a single type of mutant enzyme. However, this type of screening is the bottleneck in directed evolution, because a maximum number of 10⁵ clones can be screened over the course of weeks or even months³ and large quantities of reagents and consumables are needed. High-throughput screening methods based on either fluorescence activated cell sorting (FACS)^4–7 or microfluidic devices⁸ increase the number of clones that can be screened and reduce the amount of consumables required. Here, we demonstrate the use of a high-throughput screening system for cellulases by combining lab-on-chip sorting devices with an emulsion-based fluorescent assay previously developed for use in flow cytometry.⁵Water–in-oil emulsions are needed to maintain the connection between genotype and phenotype by compartmentalizing individual cells expressing a mutant enzyme together with the components of the fluorescence assay corresponding to the enzyme activity.⁷ For FACS, double emulsions (water-in-oil-in-water) are required because the instrument''s mobile phase is an aqueous solution. Such double emulsions can be produced by stirring or agitation,^9,10 but the resulting emulsions are polydisperse and multiple water droplets may be scattered within a single oil droplet. In addition, large droplets tend to produce more fluorescence because there are more substrate molecules available for conversion into the fluorescent product. The emulsions are produced in bulk, so each droplet will be detected at a different time point from the start of the reaction. This means that increased fluorescence may result because an enzyme has worked on the substrate for a longer amount of time, and the fluorescence of the droplet may plateau before sorting as the enzyme consumes all the available substrate. Cell loading is difficult to control because the average number of cells per droplet scales with droplet volume. Also, if several inner droplets, containing cells with different activities, are encapsulated within the same outer droplet, false positives may occur upon sorting. Consequently, it is impossible to differentiate fluorescence changes due to enzyme activity from those due to other effects using polydisperse double emulsions in FACS, but it is possible to achieve plus/minus screening,⁴ separating cells with activity from those without.Droplet microfluidics overcomes many of the drawbacks of high-throughput enzyme sorting with FACS. Both the size and composition of the droplets can be tuned precisely. Furthermore, once the enzyme is mixed with the substrate, the incubation time can be controlled and all compartments will have the same conditions in terms of concentration and total number of substrate molecules. Although cell loading is still subject to Poisson statistics, the probability for cells to be loaded into a given droplet is the same and can be adjusted by tuning the input cell density. These characteristics make the microfluidic method more sensitive, flexible, and quantitative at detecting changes in enzyme activity than the FACS-based sorting of double emulsions.Here, we report a method in which droplet microfluidics is used to sort libraries containing different percentages of cells expressing cellulase activity and demonstrate enrichment of the cells expressing active cellulases. The entire process is summarized in Figure ​Figure11.Open in a separate windowFIG. 1.General overview of cellulase screening using droplet microfluidics. In the emulsification device, suspensions of yeast surface displayed libraries are co-flowed with the substrate solution at equal flow rates to a drop-forming junction where they mix. A stream of perfluorinated oil then breaks the aqueous mixture into monodisperse water-in-oil emulsions. Within each droplet, the cellulase reaction starts after compartmentalization and the fluorescent product is formed by a coupled enzymatic cascade in droplets containing cells that express the active enzyme. After a fixed incubation time, the emulsion droplets are re-injected into a microfluidic sorting device, where they are analyzed and sorted based on their fluorescence.To detect cellulase activity, we designed an assay that uses a chain of coupled enzymatic reactions to yield fluorescence corresponding to cellulase activity without needing artificial substrates (which may lead to confounding effects, such as improved binding of the enzyme specifically to the artificial compound but not the natural substrate). In this method, cellulase hydrolyzes cellulose, its natural substrate, into monosaccharides and oligosaccharides that are further detected by the enzymatic cascade⁵ (Figure ​(Figure11).Based on previous FACS experiments, no difference in activity can be detected between the positive and the negative droplets before 2 h incubation time.⁵ Based on these observations, we expected the cells to require more than 2 h of incubation in droplets for the reaction to develop.Emulsions were formed using a co-flow flow-focusing Polydimethylsiloxane device prepared by soft lithography as previously described⁸ and using fluorocarbon oil containing 1% (v/v) Krytox-PEG-Krytox detergent synthesized as reported in an earlier study.^11,14 The solutions, one containing library cells (S. cerevisiae YPH500 cells, Agilent Technologies, Santa Clara, USA) and the other with the substrate,¹⁴ were mixed at the same flow rate, giving a one-to-one mixing ratio. The library cells were a defined mixture of cells transformed with cel5A pESC-Trp (positive cells) or empty pESC-Trp (negative cells). The two solutions therefore mixed just prior to encapsulation, minimizing the chance that fluorescent products would enter neighboring droplets. The substrate solution contained carboxymethyl cellulose (CMC), which has a high viscosity. To prevent fluctuations in the flow of substrate during the emulsification process, we optimized the flow rate and the concentration of CMC and found that a CMC concentration of 0.33% (w/v) produced monodisperse emulsions.We discovered that the HOx required for the enzymatic cascade causes droplet coalescence. HOx alone was sufficient to cause the observed change in droplet stability because droplets containing only hexose oxidase in buffer exhibited the same amount of coalescence as those containing the full set of assay components. We hypothesized that the enzyme might be surface active, disturbing the emulsion interface, but emulsions of an inactivated form of the enzyme were stable (Figure 2(a)). One possible explanation is that active HOx may interact with the detergent through the active site. Adding bovine serum albumin (BSA), which is known to have a stabilizing effect,¹² to the mixture improved droplet stability (Figure 2(a)). Emulsions of the assay mixture with BSA were stable for more than 1 day at room temperature.Open in a separate windowFIG. 2.(a) Transmission light micrographs of water-in-perfluorinated-oil emulsions produced using the microfluidic emulsification devices after 2 h incubation at room temperature. The emulsions contain 3 U/ml HOx either in its native form (left image), inactivated by heating at 99 °C for 20 min (middle image), or supplemented with 1 mg/ml BSA (right image). (b) Images of the results of the agar plate Congo Red cellulase assay before and after sorting, with the percentage of positive colonies indicated. The cells expressing cellulase activity show clear hallos.The time required for the cellulase reaction to produce detectable quantities of fluorescent product was monitored using the droplet screening instrument. These devices proved to have a higher sensitivity than the FACS system because the optics are designed for the droplet size selected for the assay. We were able to detect cellulase activity just 20 min after the compartmentalization of cells. This shorter incubation time allowed us to couple the emulsification device directly to the droplet sorting device using a short piece of tubing. The rate of emulsion flow and the dimensions of the tube set the droplet incubation time.Using the optimized conditions, we used droplet microfluidics to sort cellulase-expressing cells from a set of reference libraries. The reference libraries were created by mixing different concentrations of positive S. cerevisiae YPH500 cells expressing Cel5A cellulase and negative S. cerevisiae YPH500 cells transformed with the pESC-Trp empty vector. The mixed populations were emulsified together with the assay components in water-in-perfluorinated-oil emulsions and incubated at room temperature for 20 min. The gated population was sorted and the cells were spread on yeast nitrogen base casaminoacids (YNB CAA) Glu agar plates. An aliquot of the reference library was also plated on agar plates prior to sorting. Approximately, 100 cells before and after sorting were transferred to YNB CAA CMC Gal/Raf induction plates, and the Congo red assay¹³ was used to detect cells expressing cellulase. In this assay, colonies of positive cells developed transparent halos around them.¹⁴ The results before and after sorting are presented in Figure 2(b).We enriched cellulase-expressing cells from a pool of negative cells, regardless of the starting concentration of positive cells. We were able to isolate the cellulase-expressing cells even when starting from a low percentage of active cells (0.1%). We obtained high enrichment factors of up to 300 when starting from low concentrations of positive cells, and we were able to sort to a purity of greater than 90%. These results exceed those obtained by comparable experiments using FACS.⁵In conclusion, we developed a high-throughput screening system for cellulase activity based on droplet microfluidics. We optimized the emulsification conditions to produce highly stable and monodisperse droplets. The low dispersity of the emulsion enables the sensitive, tunable, and quantitative detection of cellulase activity. In addition, we substantially reduced the reaction time needed for the development of a fluorescent product from 2 h to 20 min. As a result, we sorted reference libraries of cellulases with various ratios of positive to negative cells, and regardless of the starting population of positive cells we were always able to enrich the active population to a higher purity than that obtained by FACS.     

A method for reducing pressure-induced deformation in silicone microfluidics

Poly(dimethylsiloxane) or PDMS is an excellent material for replica molding, widely used in microfluidics research. Its low elastic modulus, or high deformability, assists its release from challenging molds, such as those with high feature density, high aspect ratios, and even negative sidewalls. However, owing to the same properties, PDMS-based microfluidic devices stretch and change shape when fluid is pushed or pulled through them. This paper shows how severe this change can be and gives a simple method for limiting this change that sacrifices few of the desirable characteristics of PDMS. A thin layer of PDMS between two rigid glass substrates is shown to drastically reduce pressure-induced shape changes while preserving deformability during mold separation and gas permeability.     

Fabricating scaffolds by microfluidics

In this paper, we demonstrate for the first time the technique to using microfluidics to fabricate tissue engineering scaffolds with uniform pore sizes. We investigate both the bubble generation of the microfluidic device and the application of foam as a tissue engineering scaffold. Our microfluidic device consists of two concentric tapered channels, which are made by micropipettes. Nitrogen gas and aqueous alginate solution with Pluronic^® F127 surfactant are pumped through the inner and the outer channels, respectively. We observe rich dynamic patterns of bubbles encapsulated in the liquid droplets. The size of the bubble depends linearly on the gas pressure and inversely on the liquid flow rate. In addition, monodisperse bubbles self-assemble into crystalline structures. The liquid crystalline foams are further processed into open-cell solid foams. The novel foam gel was used as a scaffold to culture chondrocytes.     

Stem cells in microfluidics

Microfluidic techniques have been recently developed for cell-based assays. In microfluidic systems, the objective is for these microenvironments to mimic in vivo surroundings. With advantageous characteristics such as optical transparency and the capability for automating protocols, different types of cells can be cultured, screened, and monitored in real time to systematically investigate their morphology and functions under well-controlled microenvironments in response to various stimuli. Recently, the study of stem cells using microfluidic platforms has attracted considerable interest. Even though stem cells have been studied extensively using bench-top systems, an understanding of their behavior in in vivo-like microenvironments which stimulate cell proliferation and differentiation is still lacking. In this paper, recent cell studies using microfluidic systems are first introduced. The various miniature systems for cell culture, sorting and isolation, and stimulation are then systematically reviewed. The main focus of this review is on papers published in recent years studying stem cells by using microfluidic technology. This review aims to provide experts in microfluidics an overview of various microfluidic systems for stem cell research.     

Robotic automation of droplet microfluidics

Droplet microfluidics enables powerful analytic capabilities but often requires workflows involving macro- and microfluidic processing steps that are cumbersome to perform manually. Here, we demonstrate the automation of droplet microfluidics with commercial fluid-handling robotics. The workflows incorporate common microfluidic devices including droplet generators, mergers, and sorters and utilize the robot''s native capabilities for thermal control, incubation, and plate scanning. The ability to automate microfluidic devices using commercial fluid handling will speed up the integration of these methods into biological workflows.     

A perspective on magnetic microfluidics: Towards an intelligent future

Magnetic microfluidics has been gradually recognized as an area of its own. Both conventional microfluidic platforms have incorporated magnetic actuation for microfluidic operation and microscale object manipulation. Nonetheless, there is still much room for improvement after decades of development. In this Perspective, we first provide a quick review of existing magnetic microfluidic platforms with a focus on the magnetic tools and actuation mechanisms. Next, we discuss several emerging technologies, including magnetic microrobots, additive manufacture, and artificial intelligence, and their potential application in the future development of magnetic microfluidics. We believe that these technologies can eventually inspire highly functional magnetic tools for microfluidic manipulation and coordinated microfluidic control at the system level, which eventually drives magnetic microfluidics into an intelligent system for automated experimentation.     

Syringe-vacuum microfluidics: A portable technique to create monodisperse emulsions

We present a simple method for creating monodisperse emulsions with microfluidic devices. Unlike conventional approaches that require bulky pumps, control computers, and expertise with device physics to operate devices, our method requires only the microfluidic device and a hand-operated syringe. The fluids needed for the emulsion are loaded into the device inlets, while the syringe is used to create a vacuum at the device outlet; this sucks the fluids through the channels, generating the drops. By controlling the hydrodynamic resistances of the channels using hydrodynamic resistors and valves, we are able to control the properties of the drops. This provides a simple and highly portable method for creating monodisperse emulsions.Droplet-based microfluidic devices use micron-scale drops as “test tubes” for biological reactions.^{1, 2, 3} With the devices, the drops are loaded with cells, incubated to stimulate cell growth, picoinjected to introduce additional reagents, and sorted to extract rare specimens.^{4, 5, 6} This allows biological reactions to be performed with greatly enhanced speed and efficiency over conventional approaches: by reducing the drop volume, only picoliters of reagent are needed per reaction, while through the use of microfluidics, the reactions can be executed at rates exceeding hundreds of kilohertz. This combination of incredible speed and efficient reagent usage is attractive for a variety of applications in biology, particularly those that require high-throughput processing of reactions, including cell screening, directed evolution, and nucleic acid analysis.^{7, 8} The same advantages of speed and efficiency would also be beneficial for applications in the field, in which the amount of material available for testing is limited, and results are needed with short turnaround. However, a challenge to using these techniques in field applications is that the control systems developed to operate the devices are intended for use in the laboratory: to inject fluids, mechanical pumps are needed, while computers must adjust flow rates to maintain optimal conditions in the device.^{9, 10, 11, 12} In addition to significantly limiting the portability of the system, these qualities make them impractical for use outside the laboratory. For droplet-based microfluidic techniques to be useful for applications in the field, a general, robust, and portable system for operating them is needed.In this paper, we introduce a general, robust, and portable system for operating droplet-based microfluidic devices. In this system, which we call syringe-vacuum microfluidics (SVM), we load the reagents needed for the emulsion into the inlets of a microfluidic drop maker; using a standard plastic syringe, we generate a vacuum at the outlet of the drop maker,¹³ sucking the reagents through the channels, generating drops, and transporting them to different regions for visualization and analysis. By controlling the vacuum strength and channel resistances using hydrodynamic resistors^{14, 15, 16} and single-layer membrane valves,^{17, 18} we are able to specify the flow rates in different regions of the device and to adjust them in real time. No pumps, control computers, or electricity is needed for these operations, making the entire system portable and of potential use for field applications. To characterize the adjustability and precision of this system, we vary channel resistances and vacuum pressures while measuring the effects on drop size and production frequency. We also show how to use this to form drops of many distinct reagents simultaneously using only a single vacuum syringe.Monodisperse drop formation is the central operation in droplet-based microfluidics but can be quite challenging due to the need for precise, steady pumping of reagents; forming monodisperse drops with controlled properties is thus a stringent demonstration of the effectiveness of a control system. While there are many geometries available for microfluidic drop formation,¹⁹ in this discussion we use a simple cross-junction for its proven ability to form uniform emulsions at high rates of speed,^{20, 21} a schematic of which is shown in Fig. ​Fig.1.1. The devices are fabricated in poly(dimethylsiloxane) (PDMS) using soft lithography.²² The drop formation channels have dimensions of 25 μm in width and 25 μm in height. To enable production of aqueous drops in oil, which are the most useful for biological assays, we require hydrophobic devices, which we achieve using an Aquapel chemical treatment: we flow Aqualpel through the channels for a few seconds, flush with air, and then bake the devices for 20 min at 65 °C. After this treatment, the channels are permanently hydrophilic, as is needed for forming aqueous-in-oil emulsions. To introduce reagents into the device, we use 200 μl plastic pipette tips inserted into the channel inlets. To apply the suction, we use a 10 ml Bectin-Dickenson plastic syringe coupled to the device through a 16 G needle and PE∕5 tubing. The other end of the tubing is inserted into the outlet of the device.Open in a separate windowFigure 1Schematic of the microfluidic drop maker for use with SVM. To form water drops in oil, the device must be hydrophobic, which we achieve by treating the channels with Aquapel. The water and surfactant-containing oil are loaded into pipette tips inserted into the device inlets at the locations indicated. To pump the fluids through the drop maker, a syringe applies a vacuum to the outlet; this sucks the fluids through the drop maker, forming drops. The drops are collected into the suction syringe, where they can be stored, incubated, and reintroduced into a microfluidic device for additional processing.To begin forming drops, we fill the device with HFE-7500 fluorocarbon oil, displacing trapped air bubbles that could restrict flow and interfere with drop formation. Pipette tips containing reagents are then inserted into the device inlets, as shown in Fig. ​Fig.11 and pictured in Fig. ​Fig.2a;2a; during this step, care must be taken to not trap air bubbles under the pipette tips, as they would restrict flow. For the fluids, we use distilled water for the droplet phase and HFE-7500 with the ammonium salt of Krytox 157 FSL at 1.8 wt % for the continuous phase. The suction syringe is then connected to the device outlet; to initiate drop formation, the piston is pulled outward and locked in place with a 1 in. binder clip, as shown in Fig. ​Fig.2a.2a. This expands the air in the syringe, generating a vacuum that is transferred to the device through tubing. Since the inlet reagents are open to the atmosphere and thus maintained at a pressure of 1 atm, this creates a pressure differential through the device that pumps the fluids. As the fluids flow through the cross-channel, forces are generated that create drops, as shown in Fig. ​Fig.2b2b (enhanced online). Due to the very steady flow, the drops are highly monodisperse, as shown in Fig. ​Fig.2c.2c. After they are formed, the drops flow out of the device through the suction tube and are collected into the syringe. Depending on the emulsion formulation, drops may coalesce on the metal needle of the syringe; if so, an Upchurch fitting should be used to couple the tubing instead. The collected drops can be stored in the syringe, incubated, and reintroduced into additional microfluidic devices, as needed for the assay.Open in a separate windowFigure 2Photograph of the microfluidic drop formation device with pipette tips containing emulsion reagents and vacuum syringe for pumping (a). Distilled water is used for the droplet phase and HFE-7500 fluorocarbon oil with fluorinated surfactant for the continuous phase. The vacuum applies a pressure differential through the device that pumps the fluids through the drop maker (b) forming drops. The drops are monodisperse, due to the controlled properties of drop formation in microfluidics (c). The scale bars denote 50 μm (enhanced online).In many biological applications, drop size must be precisely controlled. This is essential, for example, when encapsulating molecules or cells in the drops, in which the number encapsulated depends on the drop size.^{3, 23, 24} With SVM, the drop size can be precisely controlled. Our strategy to accomplish this is motivated by the physics of microfluidic drop formation. In microfluidic devices, the capillary number of the flow is normally small, Ca<0.1; as a consequence, the drop formation physics follows a plugging∕squeezing mechanism, in which the drop size depends on the flow rate ratio of the dispersed-to-continuous phase.^{20, 25} By adjusting this ratio, we can thus control the drop size. To adjust this ratio, we use hydrodynamic resistor channels.^{14, 15, 16} These channels are analogous to electronic resistors in that for a fixed pressure drop (voltage) the flow rate through them (current) is inversely proportional to their resistance. By making the resistors longer or shorter, we adjust their resistance, thereby controlling the flow rate.To use resistors to control the drop size, we place three on the inlets of the cross-junction, at the locations indicated in Fig. ​Fig.3a.3a. In this configuration, the flow rate ratio depends on the resistances of the central and side resistors: shortening the side resistors increases the continuous phase flow rate with respect to the dispersed phase, thereby reducing the ratio and, consequently, the drop size, whereas lengthening it increases the drop size. By varying the ratio, we produce drops over a range of sizes, as shown in Fig. ​Fig.3b3b (enhanced online). The drop size is linear in the resistance ratio, indicating that it is linear in the flow rate ratio, as is expected for plugging∕squeezing drop formation [Fig. ​[Fig.3b3b].^{20, 25} This behavior is identical to that of pump-driven fluidics, demonstrating that SVM affords similar control.Open in a separate windowFigure 3Drop properties can be controlled using resistor channels. The resistors are placed on the inlets of the drop maker at the locations indicated in (a). The resistors enable the flow rates of the inner and continuous phases to be controlled. By varying the length ratio of the inlet resistors, we control the flow rate ratio in the drop maker. This allows the drop volume to be controlled, as shown by drop volume plotted as a function of inlet resistor length ratio in (b); varying this ratio does not significantly affect the drop formation frequency, as shown in (c). By varying the length of the outlet resistor, we control the total flow rate through the device; this allows us to form drops of constant volume, but at a different formation frequency, as shown by the plots of volume and frequency as a function of the inverse of the outlet resistor length in (d) and (e), respectively. The measured hydrodynamic resistance of a resistor channel with water as a function of length is shown as inset into (d) (enhanced online).We can also control the frequency of the drop formation using resistor channels. We place a resistor on the outlet of the device; this sets the total flow rate through the device, thereby adjusting drop frequency, as shown in Fig. ​Fig.3e3e (enhanced online). To confirm that the size and frequency control are independent, we plot size as a function of the outlet resistance and frequency as a function of the resistance ratio [Figs. ​[Figs.3c,3c, ​,3d];3d]; both are constant as a function of these parameters, again demonstrating independent control. Frequency can also be adjusted by changing the strength of the vacuum, which can be accomplished by loading a prescribed volume of air into the syringe before expansion. In this case, the vacuum pressure applied is P_fin=V_in∕V_fin×P_in, where V_in is the initial volume of air in the syringe, V_fin is the volume after expansion, and P_in is the initial pressure, which is 1 atm. By loading a prescribed volume of air into the syringe before connecting it to the device and pulling the piston, the expansion factor can be reduced, thereby lowering the vacuum strength.The flow rates through the microfluidic device depend on the applied pressure differential, which, in turn, depends on the value of the ambient pressure. Since ambient pressure may vary due to differences in altitude, the drop formation may also vary. However, since ambient pressure variations affect the inner and outer phase flows equally, this should alter the total flow rate but not the flow rate ratio. Consequently, we expect it to alter drop formation frequency but not drop size because while the frequency depends on absolute flow rate [as illustrated by Fig. ​Fig.3e],3e], drop size depends on the flow rate ratio [as illustrated in Fig. ​Fig.3b].3b]. Based on normal variations in atmospheric pressure on the surface of the Earth, we expect this to produce differences in the drop formation frequency of ∼25%, for example, when operating a device at sea level compared to at the top of a moderately sized mountain.Resistor channels allow drop properties to be controlled, equivalent to what is possible with pump-driven flow; however, they do not allow real-time control because their dimensions are fixed during the fabrication. Real-time control is often needed, for example, as it is when performing reactions in drops for the first time, in which the optimal drop size is not known. To enable real-time control, we must adjust flow rates, which can be achieved using the fluidic analog of electronic potentiometers. Single-layer membrane valves are analogous fluidic components, consisting of a control channel that abuts a flow channel.^{17, 18} By pressurizing the control channel, the thin PDMS membrane between these channels is deflected laterally, constricting the flow channel, thereby increasing its hydrodynamic resistance and reducing its flow rate.¹⁸ To use these membrane valves to vary drop size, we replace the inlet resistors with inlet valves, as shown in Fig. ​Fig.4a.4a. To set the flow rate through a path, we actuate the valve with a defined pressure. To actuate the valves, we use air-filled syringes: a 1 ml syringe is filled with air and connected to the valve control channel through tubing; an additional component, a three-way stopcock is inserted between the syringe and needle, allowing the pressure to be locked in after optimal actuation conditions are obtained. We use one syringe to control the dispersed phase valves and another to control the continuous phase valves. The valves are pressurized by compressing the air in the syringes to a defined degree using the marked graduations; this is achieved by pressing the piston to a defined graduation mark, compressing the air contained within it, thus increasing pressure. The stopcock is then switched to the off position, locking in the actuation. This simple scheme allows precise actuation of the valves, for accurate, defined flow rates in the drop maker, and controlled drop size, as shown in Figs. ​Figs.4b,4b, ​,4c4c (enhanced online). The drop size can be varied at a rate of several hertz without noticeable loss of control; moreover, changing the drop size does not affect the frequency, indicating that, again, these properties are independent, as shown by the constant drop frequency with varying pressure ratio in Fig. ​Fig.4d4d.Open in a separate windowFigure 4Single-layer membrane valves allow the drop size to be varied in real time to screen for optimal reaction conditions. The valves are positioned on the inner and side inlets, as indicated in (a). By adjusting the actuation pressures of the valves, we vary the flow rates in the drop maker, thereby changing the drop size (b), as shown by the plot of drop volume as a function of the actuation pressure ratio in (c). Varying the inlet resistance ratio does not significantly alter drop formation frequency, as shown by frequency as a function of the pressure ratio in (d). A movie of drop formation during actuation of the valves are available in the supplemental material (Ref. ²⁹). The scale bars denote 100 μm (enhanced online).Another useful attribute of SVM is that it readily lends itself to parallel drop formation²⁶ because the pressure that pumps the fluids through the channels is supplied by the atmosphere and is applied evenly over the whole outer surface of the device. This allows fluids to be introduced at equal pressures from different inlets, for forming drops with identical properties in different drop makers. To illustrate this, we use a parallel drop formation device to emulsify eight distinct reagents simultaneously; the product of this is an emulsion library, consisting of drops of identical size in which different drops encapsulate distinct reagents, useful for certain biological applications of droplet-based microfluidics.⁷ The microfluidic device consists of eight T-junction drop makers.²⁵ The drop makers share one oil inlet and outlet but each has its own inner-phase inlet, as shown in Fig. ​Fig.5.5. The oil and outlet channels are wide, ensuring negligible pressure drop through them, so that all T-junctions are operated under the same flow conditions. A distinct reagent fluid is introduced into the inner phase of each T-junction, for which we use eight concentrations of the dye Alexa Fluor 680 in water. After loading these solutions into the device through pipette tips, a syringe applies the vacuum to the outlet, sucking the reagents through the T-junctions, forming drops, as shown by the magnified images of the T-junctions during drop formation in Fig. ​Fig.5.5. Since the drop makers are identical and operated under the same flow conditions, the drops formed are of the same size, as shown in the magnified images in Fig. ​Fig.55 and in a movie available in the supplemental material.²⁹Open in a separate windowFigure 5Parallel drop formation device consisting of eight T-junction drop makers. The drop makers share a common oil inlet and outlet, both of which are wide to ensure even pressure distribution to all drop makers; support posts prevent these channels from collapsing under the suction. Each drop maker has its own inner-phase inlet, allowing emulsification of a distinct reagent. Since the drop maker dimensions and pressure differentials are constant through all drop makers, the drops formed are of the same size, as shown in the magnified images. The drops are ∼35 μm in diameter.To verify that the dye solutions are successfully encapsulated, we image a sample of the collected drops with a fluorescent microscope. The drops are confined in a monolayer between two glass plates so they can be individually imaged. They are of the same size but have distinct fluorescence intensities, as shown in Fig. ​Fig.6a.6a. To quantify these differences, we measure the intensity of each drop and plot the results as a histogram [see Fig. ​Fig.6b].6b]. There are eight peaks in the histogram, corresponding to the eight dye concentrations, demonstrating that all dyes are encapsulated successfully. The peak areas are also similar, demonstrating that drops of different types are formed in equal amounts due to the uniformity of the parallel drop formation.Open in a separate windowFigure 6Fluorescent microscope image of emulsion library created with parallel T-junction device (a). In this demonstration, eight concentrations of Alexa Fluor 680 dye are emulsified simultaneously, producing an emulsion library of eight elements. The drops are of the same size but encapsulate distinct concentrations of the dye solution, as demonstrated by the eight peaks in the intensity histograms in (b). The scale bar denotes 100 μm.SVM is a simple, accessible, and highly controlled way to form monodisperse emulsions for biological assays. It allows controlled amounts of different reagents to be encapsulated in individual drops, drop size to be precisely controlled, and the ability to form drops of different reagents at the same time, in a parallel drop formation device. These properties should make SVM useful for biological applications of monodisperse emulsions;^{1, 2, 3} the portability of SVM should also make it useful for applications in the field, particularly when no electrical power source is available. The parallel emulsification technique should also be useful for particle templating from drops, in which the particles must be of the same size but composed of distinct materials.^{26, 27, 28, 29}     

Hydrogel discs for digital microfluidics

Hydrogels are networks of hydrophilic polymer chains that are swollen with water, and they are useful for a wide range of applications because they provide stable niches for immobilizing proteins and cells. We report here the marriage of hydrogels with digital microfluidic devices. Until recently, digital microfluidics, a fluid handling technique in which discrete droplets are manipulated electromechanically on the surface of an array of electrodes, has been used only for homogeneous systems involving liquid reagents. Here, we demonstrate for the first time that the cylindrical hydrogel discs can be incorporated into digital microfluidic systems and that these discs can be systematically addressed by droplets of reagents. Droplet movement is observed to be unimpeded by interaction with the gel discs, and gel discs remain stationary when droplets pass through them. Analyte transport into gel discs is observed to be identical to diffusion in cases in which droplets are incubated with gels passively, but transport is enhanced when droplets are continually actuated through the gels. The system is useful for generating integrated enzymatic microreactors and for three-dimensional cell culture. This paper demonstrates a new combination of techniques for lab-on-a-chip systems which we propose will be useful for a wide range of applications.     

Integrating plasmonic diagnostics and microfluidics

Plasmonics is generally divided into two categories: surface plasmon resonance (SPR) of electromagnetic modes propagating along a (noble) metal/dielectric interface and localized SPRs (LSPRs) on nanoscopic metallic structures (particles, rods, shells, holes, etc.). Both optical transducer concepts can be combined with and integrated in microfluidic devices for biomolecular analyte detections, with the benefits of small foot-print for point-of-care detection, low-cost for one-time disposal, and ease of being integrated into an array format. The key technologies in such integration include the plasmonic chip, microfluidic channel fabrication, surface bio-functionalization, and selection of the detection scheme, which are selected according to the specifics of the targeting analytes. This paper demonstrates a few examples of the many versions of how to combine plasmonics and integrated microfluidics, using different plasmonic generation mechanisms for different analyte detections. One example is a DNA sensor array using a gold film as substrate and surface plasmon fluorescence spectroscopy and microscopy as the transduction method. This is then compared to grating-coupled SPR for poly(ethylene glycol) thiol interaction detected by angle interrogation, gold nanohole based LSPR chip for biotin-strepavidin detection by wavelength shift, and gold nanoholes/nanopillars for the detection of prostate specific antigen by quantum dot labels excited by the LSPR. Our experimental results exemplified that the plasmonic integrated microfluidics is a promising tool for understanding the biomolecular interactions and molecular recognition process as well as biosensing, especially for on-site or point-of-care diagnostics.     

Rapid mask prototyping for microfluidics

With the rise of microfluidics for the past decade, there has come an ever more pressing need for a low-cost and rapid prototyping technology, especially for research and education purposes. In this article, we report a rapid prototyping process of chromed masks for various microfluidic applications. The process takes place out of a clean room, uses a commercially available video-projector, and can be completed in less than half an hour. We quantify the ranges of fields of view and of resolutions accessible through this video-projection system and report the fabrication of critical microfluidic components (junctions, straight channels, and curved channels). To exemplify the process, three common devices are produced using this method: a droplet generation device, a gradient generation device, and a neuro-engineering oriented device. The neuro-engineering oriented device is a compartmentalized microfluidic chip, and therefore, required the production and the precise alignment of two different masks.     

Liquid dielectrophoresis and surface microfluidics

Liquid dielectrophoresis (L-DEP), when deployed at microscopic scales on top of hydrophobic surfaces, offers novel ways of rapid and automated manipulation of very small amounts of polar aqueous samples for microfluidic applications and development of laboratory-on-a-chip devices. In this article we highlight some of the more recent developments and applications of L-DEP in handling and processing of various types of aqueous samples and reagents of biological relevance including emulsions using such microchip based surface microfluidic (SMF) devices. We highlighted the utility of these devices for on-chip bioassays including nucleic acid analysis. Furthermore, the parallel sample processing capabilities of these SMF devices together with suitable on- or off-chip detection capabilities suggest numerous applications and utility in conducting automated multiplexed assays, a capability much sought after in the high throughput diagnostic and screening assays.     

Simplified prototyping of perfusable polystyrene microfluidics

Cell culture in microfluidic systems has primarily been conducted in devices comprised of polydimethylsiloxane (PDMS) or other elastomers. As polystyrene (PS) is the most characterized and commonly used substrate material for cell culture, microfluidic cell culture would ideally be conducted in PS-based microsystems that also enable tight control of perfusion and hydrodynamic conditions, which are especially important for culture of vascular cell types. Here, we report a simple method to prototype perfusable PS microfluidics for endothelial cell culture under flow that can be fabricated using standard lithography and wet laboratory equipment to enable stable perfusion at shear stresses up to 300 dyn/cm² and pumping pressures up to 26 kPa for at least 100 h. This technique can also be extended to fabricate perfusable hybrid PS-PDMS microfluidics of which one application is for increased efficiency of viral transduction in non-adherent suspension cells by leveraging the high surface area to volume ratio of microfluidics and adhesion molecules that are optimized for PS substrates. These biologically compatible microfluidic devices can be made more accessible to biological-based laboratories through the outsourcing of lithography to various available microfluidic foundries.     

A perspective on paper-based microfluidics: Current status and future trends

"Paper-based microfluidics" or "lab on paper," as a burgeoning research field with its beginning in 2007, provides a novel system for fluid handling and fluid analysis for a variety of applications including health diagnostics, environmental monitoring as well as food quality testing. The reasons why paper becomes an attractive substrate for making microfluidic systems include: (1) it is a ubiquitous and extremely cheap cellulosic material; (2) it is compatible with many chemical/biochemical/medical applications; and (3) it transports liquids using capillary forces without the assistance of external forces. By building microfluidic channels on paper, liquid flow is confined within the channels, and therefore, liquid flow can be guided in a controlled manner. A variety of 2D and even 3D microfluidic channels have been created on paper, which are able to transport liquids in the predesigned pathways on paper. At the current stage of its development, paper-based microfluidic system is claimed to be low-cost, easy-to-use, disposable, and equipment-free, and therefore, is a rising technology particularly relevant to improving the healthcare and disease screening in the developing world, especially for those areas with no- or low-infrastructure and limited trained medical and health professionals. The research in paper-based microfluidics is experiencing a period of explosion; most published works have focused on: (1) inventing low-cost and simple fabrication techniques for paper-based microfluidic devices; and (2) exploring new applications of paper-based microfluidics by incorporating efficient detection methods. This paper aims to review both the fabrication techniques and applications of paper-based microfluidics reported to date. This paper also attempts to convey to the readers, from the authors' point of view the current limitations of paper-based microfluidics which require further research, and a few perspective directions this new analytical system may take in its development.     

A microfluidics assisted porous silicon array for optical label-free biochemical sensing

A porous silicon (PSi) based microarray has been integrated with a microfluidic system, as a proof of concept device for the optical monitoring of selective label-free DNA-DNA interaction. A 4 × 4 square matrix of PSi one dimensional photonic crystals, each one of 200 μm diameter and spaced by 600 μm, has been sealed by a polydimethylsiloxane (PDMS) channels circuit. The PSi optical microarray elements have been functionalized by DNA single strands after sealing: the microfluidic circuit allows to reduce significantly the biologicals and chemicals consumption, and also the incubation time with respect to a not integrated device. Theoretical calculations, based on finite element method, taking into account molecular interactions, are in good agreement with the experimental results, and the developed numerical model can be used for device optimization. The functionalization process and the interaction between DNA probe and target has been monitored by spectroscopic reflectometry for each PSi element in the microchannels.     

A microfluidics approach towards high-throughput pathogen removal from blood using margination

Sepsis is an adverse systemic inflammatory response caused by microbial infection in blood. This paper reports a simple microfluidic approach for intrinsic, non-specific removal of both microbes and inflammatory cellular components (platelets and leukocytes) from whole blood, inspired by the invivo phenomenon of leukocyte margination. As blood flows through a narrow microchannel (20 × 20 µm), deformable red blood cells (RBCs) migrate axially to the channel centre, resulting in margination of other cell types (bacteria, platelets, and leukocytes) towards the channel sides. By using a simple cascaded channel design, the blood samples undergo a 2-stage bacteria removal in a single pass through the device, thereby allowing higher bacterial removal efficiency. As an application for sepsis treatment, we demonstrated separation of Escherichia coli and Saccharomyces cerevisiae spiked into whole blood, achieving high removal efficiencies of ∼80% and ∼90%, respectively. Inflammatory cellular components were also depleted by >80% in the filtered blood samples which could help to modulate the host inflammatory response and potentially serve as a blood cleansing method for sepsis treatment. The developed technique offers significant advantages including high throughput (∼1 ml/h per channel) and label-free separation which allows non-specific removal of any blood-borne pathogens (bacteria and fungi). The continuous processing and collection mode could potentially enable the return of filtered blood back to the patient directly, similar to a simple and complete dialysis circuit setup. Lastly, we designed and tested a larger filtration device consisting of 6 channels in parallel (∼6 ml/h) and obtained similar filtration performances. Further multiplexing is possible by increasing channel parallelization or device stacking to achieve higher throughput comparable to convectional blood dialysis systems used in clinical settings.     

Inertial microfluidics in contraction–expansion microchannels: A review

Inertial microfluidics has brought enormous changes in the conventional cell/particle detection process and now become the main trend of sample pretreatment with outstanding throughput, low cost, and simple control method. However, inertial microfluidics in a straight microchannel is not enough to provide high efficiency and satisfying performance for cell/particle separation. A contraction–expansion microchannel is a widely used and multifunctional channel pattern involving inertial microfluidics, secondary flow, and the vortex in the chamber. The strengthened inertial microfluidics can help us to focus particles with a shorter channel length and less processing time. Both the vortex in the chamber and the secondary flow in the main channel can trap the target particles or separate particles based on their sizes more precisely. The contraction–expansion microchannels are also capable of combining with a curved, spiral, or serpentine channel to further improve the separation performance. Some recent studies have focused on the viscoelastic fluid that utilizes both elastic forces and inertial forces to separate different size particles precisely with a relatively low flow rate for the vulnerable cells. This article comprehensively reviews various contraction–expansion microchannels with Newtonian and viscoelastic fluids for particle focusing, separation, and microfluid mixing and provides particle manipulation performance data analysis for the contraction–expansion microchannel design.     

Hand-powered microfluidics: A membrane pump with a patient-to-chip syringe interface

In this paper, we present an on-chip hand-powered membrane pump using a robust patient-to-chip syringe interface. This approach enables safe sample collection, sample containment, integrated sharps disposal, high sample volume capacity, and controlled downstream flow with no electrical power requirements. Sample is manually injected into the device via a syringe and needle. The membrane pump inflates upon injection and subsequently deflates, delivering fluid to downstream components in a controlled manner. The device is fabricated from poly(methyl methacrylate) (PMMA) and silicone, using CO₂ laser micromachining, with a total material cost of ∼0.20 USD/device. We experimentally demonstrate pump performance for both deionized (DI) water and undiluted, anticoagulated mouse whole blood, and characterize the behavior with reference to a resistor-capacitor electrical circuit analogy. Downstream output of the membrane pump is regulated, and scaled, by connecting multiple pumps in parallel. In contrast to existing on-chip pumping mechanisms that typically have low volume capacity (∼5 μL) and sample volume throughput (∼1–10 μl/min), the membrane pump offers high volume capacity (up to 240 μl) and sample volume throughput (up to 125 μl/min).     

A dynamically deformable microfilter for selective separation of specific substances in microfluidics

To study an environmental or biological solution, it is essential to separate its constituents. In this study, a 3D-deformable dynamic microfilter was developed to selectively separate the target substance from a solution. This microfilter is a fine metallic nickel structure fabricated using photolithography and electroplating techniques. It is gold-coated across its entire surface with multiple slits of 10–20 μm in width. Its two-dimensional shape is deformed into a three-dimensional shape when used for fluid separation due to hydrodynamic forces. By adjusting the pressure applied to the microfilter, the size of the gap created by deformation can be changed. To effectively isolate the target substance, the relationship between the solution flow rate and the extent of microfilter deformation was investigated. The filtration experiments demonstrated the microfilter’s ability to isolate the target substance with elastic deformation without undergoing plastic deformation. Additionally, modification of the microfilter surface with nucleic acid aptamers resulted in the selective isolation of the target cell, which further demonstrates the potential application of microfilters in the isolation of specific components of heterogeneous solutions.     

Uniform yeast cell assembly via microfluidics

This paper reports the use of microfluidic approaches for the fabrication of yeastosomes (yeast-celloidosomes) based on self-assembly of yeast cells onto liquid-solid or liquid-gas interfaces. Precise control over fluidic flows in droplet- and bubble-forming microfluidic devices allows production of monodispersed, size-selected templates. The general strategy to organize and assemble living cells is to tune electrostatic attractions between the template (gel or gas core) and the cells via surface charging. Layer-by-Layer (LbL) polyelectrolyte deposition was employed to invert or enhance charges of solid surfaces. We demonstrated the ability to produce high-quality, monolayer-shelled yeastosome structures under proper conditions when sufficient electrostatic driving forces are present. The combination of microfluidic fabrication with cell self-assembly enables a versatile platform for designing synthetic hierarchy bio-structures.