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Effective mixing is essential for biochemical reactions. In droplet-basedmicrofluidics, immediate mixing of substances upon contact in the dropletformation stage can greatly enhance the uniformity of chemical reactions.Furthermore, it eliminates the need for implementing micromixers in the chip.In our research, we conducted a comprehensive study by first employing a seriesof two-dimensional (2D) numerical simulations, followed by experimentalinvestigations using three-dimensional-printed (3D-printed) microfluidic chips.Our primary focus was on assessing the mixing efficiency within droplets.Specifically, we compared the performance of three different types of dropletgenerators: T-junction, cross-junction, and a novel asymmetric design withvarious angles. Our evaluation criteria encompassed mixing efficiency, dropletdiameter, and droplet eccentricity. Our findings indicate that 2D numericalsimulations can serve as a valuable tool for qualitatively analyzing two-phaseflows and the droplet generation process, particularly in quasi-two-dimensionaldevices. The relative simplicity of such simulations renders them readilyapplicable, specifically in complex microfluidic geometries. Regarding mixingefficiency, we observed that the asymmetric droplet generators outperformed thecross-junction configuration but fell slightly short of the mixing efficiencyachieved by the T-junction. Additionally, while the mixing index in theasymmetric generators closely matched that of the T-junction, these asymmetricgenerators produced smaller droplets. Our study suggests that the novelasymmetric droplet generators offer a significant advantage by simplifying thedesign of microfluidic devices. This is achieved by facilitating both dropletformation and rapid reagent mixing within the droplets while concurrentlymaintaining a small droplet diameter.

Investigating Mixing Efficiency in Droplets: A Comprehensive Study of Numerical Modeling and Experimental Testing in 3D-Printed Microfluidic Devices