3D-Printed Microfluidic Chip System with Integrated Fluidic Breakers and Phaseguide Fluid Structures for Optimal Passive Mixing

3D printing offers great potential for rapid and cost-effective fabrication of microfluidic lab-on-a-chip systems. Through a comparative approach, we implemented staggered herringbone mixer (SHM), Tesla mixer, and split and recombine mixer (SAR), along with a basic unperturbed channel into one chip and performed comparative mixing efficiency experiments. We also introduced a phaseguide-based, T-shaped stop structure at the Y-shaped inlets for bubble-free and parallel filling. The structures were analyzed with two poorly mixable dye solutions at flow rates ranging from 1 µL/min to 200 µL/min. The mixing efficiency was evaluated using optical gray value analysis and compared against diffusion-based mixing. The fluid-aligning phaseguides in the 3D-printed system were shown to work. Among the three different mixing structures tested, SHM exhibited the best mixing efficiency at all tested flow rates. Uniformly designed SHM structures contain a region of poor mixing between the two zones of turbulence. In a non-uniform design, fluid breakers were placed between two SHM units to redirect poorly mixed fluids to the edges, resulting in 100% mixing efficiency across all measured flow rates. These results, especially SHM with fluid breakers, support the development of cost-effective injection-molded lab-on-a-chip systems with improved mixing functionalities at close range instead of simple long-length meandric systems.