Fabrication of 3D printed modular microfluidic system for generating and manipulating complex emulsion droplets

We designed a modular microfluidic system for generating droplets using a three-dimensional (3D) printer. This system was manufactured as a modular system with multipurpose droplet generation flexibility. The various types of emulsion droplets can be generated by changing the combination of the incorporated modules. All modules are interconnected based on a novel coupling system that facilitates assembly and disassembly, and leakages do not occur even for pressures of the order of ~ 40 kPa. We demonstrate the capacity of the system to generate emulsion droplets, ranging from single to complicated dual-core double-emulsion droplets. Droplet sizes in the range of 50–500 μm were obtained by controlling the flow rate and the generation frequency in the range of 1–100 Hz. Furthermore, an electrode module was developed to demonstrate different electrohydrodynamic phenomena, such as the shape deformation, coalescence, breakup, and others. This 3D printed modular microfluidic system makes it possible to meet the needs of the end-user, and can be applied to bioassays, material synthesis, and other applications.