Mode Transition of Droplet Formation in a Semi-3D Flow-Focusing Microfluidic Droplet System

Uniform droplets have significant potential in many biological applications due to their higher surface area to volume ratio. This paper proposed a semi-three-dimensional (sime-3D) flow-focusing microfluidic system, which was fabricated using the multi-layer soft lithography method. Based on the semi-3D structure, we focus on droplets formation modes and droplet uniformity at different bulk concentration of surfactant. The relationships between droplets uniformity, droplets breakup processes (jetting mode, dripping mode and tip-streaming mode) and surfactant concentration was investigated. It was found that three droplet generation modes occur through adjusting the pressure ratio in two inlet channels and the concentration of surfactant in continuous phase liquid. The jetting mode would transform to the dripping mode or the tip-streaming mode as the pressure ratio in different surfactant concentrations increased. Furthermore, the uniformity of droplets could be improved through the transition of jetting to dripping mode. We assumed that the uniformity declined through the transition of jetting to tip-streaming, and explored the specific transitions from jetting to dripping mode and tip-streaming mode. Dripping mode leads to high droplet uniformity, and generation frequency decreases with increasing pressure ratio. Tip-streaming mode is considered as an extreme state of jetting mode, leading to higher formation frequency and smaller droplet size at low uniformity.