Microfluidic techniques for production of uniform droplets usually rely on the use of two immiscible liquids (e.g. water-in-oil emulsions). It has been shown recently that a continuous gas flow instead of a second liquid carrier can be used as an alternative approach in droplet microfluidics. In this work we experimentally investigate the generation of liquid water droplets within air in flow-focusing configurations. Over a wide range of flow conditions we identify six distinct flow regimes inside the microchannel: Co-flowing, Threading, Plugging, Dripping, Multi-Satellite Formation, and Jetting. Flow regimes and their transitions are plotted and characterized based on the Weber number (We) of the system. We further investigate the impact of liquid microchannel size on the flow maps. Generation frequency, morphology, and monodispersity of the droplets are characterized in more detail in the Dripping regime. Generation frequency can be related to the product of the liquid and gas flow rates. However, droplet morphology (length and width) is more dependent on the gas flow rate. We demonstrate the production of monodisperse droplets (d < 100 µm and σ/d < 5 %) up to kHz formation rates in liquid-gas microfluidic systems for the first time. The results of this work provide practical and useful guidelines for precise, oil-free delivery of ultra-small volumes of fluid which can be integrated in lab-on-a-chip systems for a variety of applications in biochemical research and material synthesis.

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In this paper a new microfluidic technique is proposed for ultra-high-throughput generation of micron-sized water droplets using a high-speed air. We use a 3D flow-focusing microchannel fabricated in PDMS by multilayer lithography process. The interaction of liquid and gas created three main flow conditions which are: Flooded, Dripping, and Jetting. We characterize the Jetting regime where a capillary jet surrounded by the air breaks up into uniform array of droplets. Frequency of generation and droplet size are reported for the jetting regime under different liquid and gas flows. It was possible to obtain 25μm diameter droplets and much higher frequencies (f≈120 kHz) compared to the state-of-the-art microfluidic systems. We believe the advantages of this platform enables many novel applications such as high-throughput screening of airborne targets and large-scale production of oil-free particles. The 3D structure of this device also eliminates the limitation of the conventional droplet-based microfluidic systems, namely clogging issues due to particle aggregation.