The performance of a micro-acousto-fluidic device designed for microparticle trapping is simulated using a three-dimensional (3D) numerical model. It is demonstrated by numerical simulations that geometrically asymmetric architecture and actuation can increase the acoustic radiation forces in a liquid-filled cavity by almost 2 orders of magnitude when setting up a standing pressure half wave in a microfluidic chamber. Similarly, experiments with silicon-glass devices show a noticeable improvement in acoustophoresis of 20-μm silica beads in water when asymmetric devices are used. Microparticle acoustophoresis has an extensive array of applications in applied science fields ranging from life sciences to 3D printing. A more efficient and powerful particle manipulation system can boost the overall effectiveness of an acoustofluidic device. The numerical simulations are developed in the COMSOL Multiphysics® software package (COMSOL AB, Stockholm, Sweden). By monitoring the modes and magnitudes of simulated acoustophoretic fields in a relatively wide range of ultrasonic frequencies, a map of device performance is obtained. 3D resonant acoustophoretic fields are identified to quantify the improved performance of the chips with an asymmetric layout. Four different device designs are analyzed experimentally, and particle tracking experimental data qualitatively supports the numerical results.

Opportunities to improve thermal management in electronic devices are currently hindered by processing constraints that limit thermal conductivity in polymer‐matrix composites. Active patterning of filler particles is a promising route to improve conductivity while retaining processability by improving particle contact density and directing heat along optimized pathways. This study employs acoustic patterning to align and compact filler particles into stripes during stereolithographic 3D printing. This approach produces polymer‐based composite materials with highly efficient embedded heat transport pathways which reach 95 vol% particle utilization (relative to the parallel conduction upper limit). These composites exhibit anisotropic thermal conductivity up to 300% higher than unpatterned composites, with in‐plane anisotropy ratios of up to 350%. Combining this high conductivity with 3D printing enables materials with engineered heat networks that optimize transport from hot spots to heatsinks while maintaining low viscosity for fast particle patterning and for infiltration around electronic components. Finally, numerical simulations of acoustic assembly of particles with varied geometry, when compared to experimentally characterized particle packing, illuminate pathways for further improving conductivity by optimizing particle geometry for alignment and stacking of particles with maximum contact surface area.

This work presents three-dimensional (3D) numerical analysis of acoustic radiation force on an elastic microsphere suspended in a viscous fluid. Acoustophoresis of finite-sized, neutrally buoyant, nearly incompressible soft particles may improve by orders of magnitude and change directions when going through resonant vibrations. These findings offer the potential to manipulate and separate microparticles based on their resonance frequency. This concept has profound implications in cell and microparticle handling, 3D printing, and enrichment in lab-on-chip applications. The existing analytical body of work can predict spheroidal harmonics of an elastic sphere and acoustic radiation force based on monopole and dipole scatter in an ideal fluid. However, little attention is given to the complex interplay of resonant fluid and solid bodies that generate acoustic radiation. The finite element method is used to find resonant modes, damping factors, and acoustic forces of an elastic sphere subject to a standing acoustic wave. Under fundamental spheroidal modes, the radiation force fluctuates significantly around analytical values due to constructive or destructive scatter-incident wave interference. This suggests that for certain materials, relevant to acoustofluidic applications, particle resonances are an important scattering mechanism and design parameter. The 3D model may be applied to any number of particles regardless of geometry or background acoustic field.