3D Printed Microfluidic Separators for Solid/Liquid Suspensions

This study investigates the fabrication of 3D-printed microfluidic devices for solid/liquid separation, focusing on additive manufacturing technologies. Stereolithography (SLA) and fused filament fabrication (FFF) were used to create microseparators with intricate designs optimized for separation efficiency. Model suspensions containing quartz sand, nano-calcium carbonate, and talc-based baby powder in water were prepared using an electric magnetic stirrer and conveyed into the microseparator via a peristaltic pump. Different flow rates were tested to evaluate their influence on the separation efficiency. The highest separation efficiency for the model systems was observed at a flow rate of 200 mL min−1. This was due to the increased turbulence at higher flow rates, which hindered the secondary flow perpendicular to the primary flow direction. The particle size distribution before and after separation was analyzed using sieve and laser diffraction, and particle morphology was inspected by scanning electron microscopy. The laser diffraction analysis revealed post-separation particle size distributions, indicating that Outlet 1 (external stream) consistently captured larger particles more effectively than Outlet 2 (internal stream). This work highlights the potential of additive manufacturing to produce customized microfluidic devices, enabling rapid prototyping and fine-tuning of complex geometries, thus enhancing separation efficiency across various industrial applications.