Comparative experimental and numerical study of mixing efficiency in 3D-printed microfluidic droplet generators: T junction, cross junction, and asymmetric junctions with varying angles

In droplet-based microfluidics, rapid mixing during droplet formation enhances reaction uniformity, eliminating the need for micromixers. In this research, we conducted a comprehensive study by first employing a series of two-dimensional (2D) numerical simulations, followed by experimental investigations using 3D-printed microfluidic chips. We compared the mixing efficiency, droplet diameter, and droplet eccentricity of three different types of droplet generators: T junction, cross junction, and asymmetric droplet generators with various angles. Regarding mixing efficiency, we observed that the asymmetric droplet generators outperformed the cross junction by 30 % but fell slightly short of the mixing efficiency achieved by the T junction (1 %). Additionally, while the mixing index in the asymmetric generators closely matched that of the T junction, these asymmetric generators produced smaller droplets by 72 %. Increasing the angle in asymmetric droplet generators resulted in enhanced mixing efficiencies and an increase in droplet diameters. The asymmetric junction with a 30° angle could achieve a mixing efficiency of up to 80 %. Additionally, an analysis of the dispersed phase flow rate revealed that higher flow rates lead to larger droplet sizes and reduced mixing efficiencies. The asymmetric droplet generators improve mixing efficiency facilitating rapid reagent mixing, all while maintaining a small droplet diameter.