Micromixers are crucial components to carry out chemical, biomedical and bio-chemical analyses on µTAS (micro total analysis system) or Lab-on-chips. Simple planar type passive mixers are always most desirable over three dimensional or complex geometries of passive mixers or active mixers as they are less expensive, easy to fabricate, and easy to integrate into complex miniaturized systems. However, at very low Reynolds numbers (0 to 100), due to the inherent laminar nature of the microfluidic flows, mixing remains challenging in passive mixers. Previous studies reported that serpentine square-wave micromixer is one of the simple and effective passive device for micromixing. In the present study, to further enhance the mixing efficiency of the device, horizontal straight portions of serpentine square wave mixer are replaced with convergent-divergent passages and the mixing performance of both mixers are evaluated in the Re range of 0 to 100. It is observed in the low Re (0 to 10), mixing in the square wave mixer with convergent-divergent portions (SQW-CD mixer) is governed completely by pure diffusion as in the case of square wave mixer with straight horizontal portions (SQW mixer). However, at high Re (Re > 10), the presence of convergent-divergent portions in the SQW-CD mixer considerably intensify the stretching and folding of samples in the mixing channel. Additionally, the extra recess available at the bends of SQW-CD mixer creates recirculation zones in the mixer. Therefore, a significant improvement in the mixing performance is achieved at high Re (Re > 10) for SQW-CD mixer as compared to conventional SQW mixer. This would allow shorter mixing lengths for SQW-CD mixer as compared to Sq wave mixer. However, with increase in Re, the rise in pressure drop is considerably high for SQW-CD mixer as compared to SQW mixer.

This study looked at optimizing the geometrical shape of a simple T-mixer using Bernstein polynomials-based shape optimization technique to improve the mixing of the T-mixer. Passive micromixers of planar geometry are preferred in a wide range of applications such as lab-on-chips and chemical processing applications, due to their ease of fabrication and low processing costs. Studies conducted on T-mixers have revealed that the performance of T-mixers at low Re (<30) is dismal. At low Reynolds number flows, the mixing is completely dominated by diffusion because of laminar flow conditions. In the present work, an attempt to improve the mixing performance of the T-mixer was made and a nearly three-fold improvement in performance was reported. The adjoint-based shape optimization technique was employed to optimize the wall profile without losing the advantage of the ease of fabrication. The T-mixer boundaries were represented parametrically using Bernstein polynomials that could take any shape within a constrained plane. Different shapes can be generated for different polynomial orders. A limit on the minimum channel thickness (60 microns) was imposed, while the inlet and outlet boundary lengths were fixed. For this particular geometry, the 12th-order polynomial exhibits an optimized shape for maximum mixing performance. The optimized shape of the T-mixer also shows significant improvement in mixing compared to a conventional T-mixer with a reduced channel thickness of 60 microns.