Expressions for the axial pressure profiles in a cylindrical channel and between parallel plates or a rectangular channel with large aspect ratio, with Maxwell slip gas flow are derived from first principles. The resulting expressions, which only involve the inlet and outlet pressures and the channel dimensions, will be useful in modelling or simulations of channel flows at Knudsen numbers in the range 0.001–0.1, such as in MEMS and NEMS. The expression for a cylindrical channel is validated by deriving from it an expression for the channel mass flow, which is shown to agree with a known expression for the mass flow through cylindrical channels with Maxwell slip flow. The expression for flow between parallel plates is found to agree with the zeroth order relation derived by Arkilic et al. using perturbation analysis. The effect of the accommodation coefficient on the pressure profile in a cylindrical channel is shown.

In the last decade, three-dimensional (3D) printing has allowed the field of complex microfluidic channels to expand rapidly towards channels with variable cross-sections (i.e., beyond simple rounded media with a constant diameter) and channels. Whose trajectory can be outside a single plane and has gained numerous macro- and nanoscale manufacturing advances. Three-dimensional printing is being explored for various biomedical applications and the fabrication of nanomedicines using additive manufacturing techniques. Employing 3D-printed templates for macro-to-micro interfacing, a passively operated microfluidic device was designed. The research seeks to fabricate a biodevice that enables insulin microdosing, creating a subsystem like a microvalve and a microchannel matrix using additive manufacturing techniques. Our systems feature designs that enhance fluid dynamics without affecting the stability of the insulin. We propose using Humalog insulin in tropical climates (up to 30°C) without refrigeration for 28 days. The microvalve has a spiral trajectory with four outlet channels distributed along it. These channels align with the microchannels organized in a 10 mm x 15 mm matrix with 25 microchannels, each with a 770 µm internal diameter. The system delivers a dose of 2,3 mL in 6 minutes. We designed these systems for insulin micro-dosing, but they can also serve similar devices for other drugs.

Microfluidic technology has become a powerful tool for several applications in chemistry, physics, biology, and engineering. Benefiting from the advantages of flowing fluids in the laminar regime, droplet-based microfluidics enable the development of various delivery systems based on food-grade emulsions, such as multiple emulsions, microgels, microcapsules, solid lipid micro-particles, and giant liposomes. Besides, by manipulating fluids on a micrometer scale with low-energy demand, it is possible to control the size, shape, and dispersity of droplets generated, which makes microfluidic emulsification an excellent strategy to modulate delivery system properties depending on the entrapped compound type. Thus, this review points out the most current advances in droplet-based microfluidic processes, in which food-grade materials were successfully utilized to develop simple and complex delivery systems. In that context, we sum-marized the principles of droplet-based microfluidics, introducing the most common microde-vices geometries, manufacturing materials, and forces involved in the different droplet generation processes within the microchannels. Subsequently, the encapsulated compound type, classified as lipophilic or hydrophilic functional compounds, was used as a starting point to present current advances in delivery systems based on food-grade emulsions and assembly using microfluidic technologies. Finally, we discuss the limitations and perspectives of scale-up in droplet-based microfluidic approaches, including the challenges that have limited the transition of microfluidic processes from lab-scale to industrial-scale.

Rapid isolation of white blood cells (WBCs) from whole blood is an essential part of any WBC examination platform. However, most conventional cell separation techniques are labor-intensive and low throughput, require large volumes of samples, need extensive cell manipulation, and have low purity. To address these challenges, we report the design and fabrication of a passive, label-free microfluidic device with a unique U-shaped cross-section to separate WBCs from whole blood using hydrodynamic forces that exist in a microchannel with curvilinear geometry. It is shown that the spiral microchannel with a U-shaped cross-section concentrates larger blood cells (e.g., WBCs) in the inner cross-section of the microchannel by moving smaller blood cells (e.g., red blood cells (RBCs) and platelets) to the outer microchannel section and preventing them from returning to the inner microchannel section. Therefore, it overcomes the major limitation of a rectangular cross-section where secondary Dean vortices constantly enforce particles throughout the entire cross-section and decrease its isolation efficiency. Under optimal settings, more than 95% of WBCs can be isolated from whole blood under high-throughput (6 ml/min), high-purity (88%), and high-capacity (180 ml of sample in 1 hour) conditions. High efficiency, fast processing time, and non-invasive WBC isolation from large blood samples without centrifugation, RBC lysis, cell biomarkers, and chemical pre-treatments make this method an ideal choice for downstream cell study platforms.

Fluid mechanics of flow in hydrophobic, rectangular microchannels with finite aspect ratios is of paramount importance. In such microchannels, not only the effect of the side walls should be taken into account, but also the classical assumption of no-slip boundary condition (BC) is no longer valid at the solid-liquid interface. Accordingly, slip flow can occur in microchannels fabricated from surfaces with low wetting conditions, hydrophobic surfaces. Determining the interactions of liquid molecules adjacent to solid surface is still a challenging issue, and it is especially important in small scale domains. Herein, the fluid mechanics of flow through rectangular hydrophobic microchannels has been reconsidered by taking into account the general Navier-slip BCs at the solid-liquid interface. For fully developed incompressible flow in microchannels at low Reynolds number, partial differential equation (PDE) of the momentum equation simplifies to the classical Poisson equation. Accordingly, by analytically solving the Poisson equations with general Navier-slip BCs, the most general forms of velocity distributions, flow rate, friction factor and Poiseuille number have been obtained.

This study presents a new form of velocity distribution in laminar liquid flow in rectangular microchannels using the eigenfunction expansion technique. Darcy friction factor and Poiseuille number are also obtained analytically. Due to the symmetry of the solutions, the effects of changing the aspect ratio from 0 to ∞ are also discussed. Using finite element method (FEM), the obtained analytical results are further compared with the 3D numerical simulations for the rectangular microchannels with different range of aspect ratio and pressure gradient, and excellent agreements were found. These findings provide additional insights in interpreting the results of the pressure-driven flows in finite aspect ratio microchannels, in which very precise comparison with the macroscale theory is crucial.