Pulse Driven Injection in an Additive-Manufactured Microchannel for Rapid Mixing of Stratified Concurrent Flow and...

Laminar co-flow in microchannels typically results in stratified streams with diffusion-limited mixing. This work presents an additively manufactured microfluidic platform that integrates a pulse tank and a transverse injection nozzle into an otherwise straight channel, enabling pulse-driven mixing and droplet generation using air-pressure actuation alone. In Device A, transverse pulsed injection disrupted the stratified interface and significantly enhanced mixing compared with the no-pulse case, as confirmed by an entropy-based mixing index. In Device B, pulsed injection into a continuous oil phase enabled stable droplet-on-demand generation with pressure-tunable droplet diameter in a straight circular channel. The devices operated in a laminar regime, with representative Reynolds, Péclet, and capillary numbers confirming diffusion-limited baseline mixing and stable dripping-type droplet formation. The results demonstrate that pulse-driven injections in a simple, additively manufactured geometry provide an effective, low-complexity approach to mixing enhancement and droplet generation without external fields or complex channel designs.