Enhancing the Design of Microdevices: The Role of Computational Fluid Dynamics and Experimental Investigation

The growing use of microfluidic-based devices necessitates an analysis of flow characteristics through both experimental methods and computational fluid dynamic (CFD) simulations. CFD simulations facilitate the investigation of various devices, including medical sensors, by providing detailed insights into flow behavior. In this study, we conducted experimental and CFD analysis of the microfluidic flow in three devices: a COVID-19 rapid test kit, a blood glucose kit, and a PDMS kit. Our findings revealed that the changes in wall adhesion (contact angles) during the capillary flow could cause significant deviation from theoretical flow speed predictions. A hemodynamic analysis of the blood glucose kit and PDMS kit showed that capillary filling decreased in length, and flow speed could depend on the microchannel diameter. CFD results indicated the prominent role of porosity in the simulation of porous media material such as the COVID-19 test kit, as well as surface tension coefficients and wall adhesion (contact angles) in blood glucose kits and PDMS kits. Therefore, considering adaptive dynamic contact angles in CFD simulation software such as Ansys-Fluent 2024 could result in a more accurate prediction than simplified theoretical techniques, which is useful for sensor optimization and development.