Two-phase flow microfluidics is emerging as a popular technology for a wide range of applications involving high throughput such as encapsulation, chemical synthesis and biochemical assays. Within this platform, the formation and merging of droplets inside an immiscible carrier fluid are two key procedures: (i) the emulsification step should lead to a very well controlled drop size (distribution); and (ii) the use of droplet as micro-reactors requires a reliable merging. A novel trend within this field is the use of additional active means of control besides the commonly used hydrodynamic manipulation. Electric fields are especially suitable for this, due to quantitative control over the amplitude and time dependence of the signals, and the flexibility in designing micro-electrode geometries. With this, the formation and merging of droplets can be achieved on-demand and with high precision. In this review on two-phase flow microfluidics, particular emphasis is given on these aspects. Also recent innovations in microfabrication technologies used for this purpose will be discussed.

We discuss a microfluidic system in which (programmable) local electric fields originating from embedded and protected electrodes are used to control the formation and merging of droplets in a microchannel. The creation of droplets-on-demand (DOD) is implemented using the principle of electrowetting. Combined with hydrodynamic control, the droplet size and formation frequency can be varied independently. Using two synchronized DOD injectors, merging-on-demand (MOD) is achieved via electrocoalescence. The efficiency of MOD is 98% based on hundreds of observations. These two functionalities can be activated independently.

We integrated electrowetting into a microfluidic flow focusing device to study drop generation under the influence of electric fields. Using both the dispersed phase inlet pressure and the applied voltage as control parameters, we find that the range of drop sizes and the drop generation rate can be controlled in a much finer way than with hydrodynamics alone. In particular a “conical spray” regime occurring at a voltage of O(50 V) allows for continuous tuning of the (highly monodisperse) drop diameter from ≈5 to 50 μm at a fixed continuous flow rate.

Electrowetting (EW) is widely used in digital microfluidics for the manipulation of drops sandwiched between two parallel plates. In contrast, demonstrations of closed microfluidic channels enhanced with EW functionality are scarce. Here, we report a simple, low-cost method to construct such microchannels enclosed between two glass plates, each of which comprises electrodes and insulating layers. Our method uses soft imprint lithography with thiolene precursors to design the channel geometry. UV exposure is used to seal the chips permanently and a silanization treatment renders all inner channel surfaces hydrophobic. Compared to earlier polydimethylsiloxane-based designs, this method allows us to make microchannels with smaller dimensions (down to 10 microns), lower aspect ratios (down to height/length = 1/10), and symmetric electrodes both on the top and the bottom of the channel. We demonstrate the new capabilities with two examples: (i) EW-enhanced drop generation in a flow focusing geometry allows precise and continuous control on drop diameter in the range ≈ 1–15 microns while maintaining monodispersity; (ii) EW allows tuning of the excess water pressure needed to displace oil in a microchannel, leading to spontaneous imbibition at EW number η > 0.89.