3D-printing (3DP) technology has been developing rapidly. However, limited studies on the contribution of 3DP technology, especially multimaterial 3DP technology, to droplet-microfluidics have been reported. In this paper, multimaterial 3D-printed devices for the pneumatic control of emulsion generation have been reported. A 3D coaxial flexible channel with other rigid structures has been designed and printed monolithically. Numerical and experimental studies have demonstrated that this flexible channel can be excited by the air pressure and then deform in a controllable way, which can provide the active control of droplet generation. Furthermore, a novel modular microfluidic device for double emulsion generation has been designed and fabricated, which consists of three modules: function module, T-junction module, and co-flow module. The function module can be replaced by (1) Single-inlet module, (2) Pneumatic Control Unit (PCU) module and (3) Dual-inlet module. Different modules can be easily assembled for different double emulsion production. By using the PCU module, double emulsions with different number of inner droplets have been successfully produced without complicated operation of flow rates of different phases. By using single and dual inlet module, various double emulsions with different number of encapsulated droplets or encapsulated droplets with different compositions have been successfully produced, respectively.

3D printing with a high degree of spatial and compositional precision could open new avenues to the design and fabrication of functional composites. By combining the direct ink writing and microfluidics, a multimaterial 3D printing system for fabricating textured composites with liquid inclusions of programmable spatial distribution and compositions is reported here. Phase diagrams for the rational selection of desired printing parameters are determined through a combination of simple theoretical analysis and experimental studies. 1D, 2D, and 3D structures programmed with desired inclusion patterns and compositions are fabricated. Moreover, the versatility of this 3D printing framework in fabricating layered composite beams of tunable thermal property and self‐healing materials is demonstrated. The proposed multimaterial microfluidic 3D printing framework could be broadly applicable for structural composites and soft robotic devices.

Novel low-cost 3D-printed plug-and-play microfluidic devices have been developed for droplet generation and applications. By combining a commercial tubing with the printed channel design we can generate well-controlled droplets down to 50 μm.

Droplet microfluidics has become the most promising subcategory of microfluidics since it contributes numerous applications to diverse fields. However, fabrication of microfluidic devices for droplet formation, manipulation and applications is usually complicated and expensive. Three-dimensional printing (3DP) provides an exciting alternative to conventional techniques by simplifying the process and reducing the cost of fabrication. Complex and novel structures can be achieved via 3DP in a simple and rapid manner, enabling droplet microfluidics accessible to more extensive users. In this article, we review and discuss current development, opportunities and challenges of applications of 3DP to droplet microfluidics.

Droplet-based microfluidic devices provide a powerful platform for material, chemical and biological applications based on droplet templates. The technique traditionally utilized to fabricate microfluidic emulsion generators, i.e. soft-lithography, is complex and expensive for producing three-dimensional (3D) structures. The emergent 3D printing technology provides an attractive alternative due to its simplicity and low-cost. Recently a handful of studies have already demonstrated droplet production through 3D-printed microfluidic devices. However, these devices invariably use purely two-dimensional (2D) flow structures. Herein we apply 3D printing technology to fabricate simple and low-cost 3D miniaturized fluidic devices for droplet generation (single emulsion) and droplet-in-droplet (double emulsion) without need for surface treatment of the channel walls. This is accomplished by varying the channel diameters at the junction, so the inner liquid does not touch the outer walls. This 3D-printed emulsion generator has been successfully tested over a range of conditions. We also formulate and demonstrate, for the first time, uniform scaling laws for the emulsion drop sizes generated in different regimes, by incorporating the dynamic contact angle effects during the drop formation. Magnetically responsive microspheres are also produced with our emulsion templates, demonstrating the potential applications of this 3D emulsion generator in chemical and material engineering.