3D printing and artificial intelligence tools for droplet microfluidics: Advances in the generation and analysis of emulsions

Droplet microfluidics has emerged as highly relevant technology in diverse fields such as nanomaterials synthesis, photonics, drug delivery, regenerative medicine, food science, cosmetics, and agriculture. While significant progress has been made in understanding the fundamental mechanisms underlying droplet generation in microchannels and in fabricating devices to produce droplets with varied functionality and high throughput, challenges persist along two important directions. On one side, the generalization of numerical results obtained by computational fluid dynamics would be important to deepen the comprehension of complex physical phenomena in droplet microfluidics, as well as the capability of predicting the device behavior. Conversely, truly three-dimensional architectures would enhance microfluidic platforms in terms of tailoring and enhancing droplet and flow properties. Recent advancements in artificial intelligence (AI) and additive manufacturing (AM) promise unequaled opportunities for simulating fluid behavior, precisely tracking individual droplets, and exploring innovative device designs. This review provides a comprehensive overview of recent progress in applying AI and AM to droplet microfluidics. The basic physical properties of multiphase flows and mechanisms for droplet production are discussed, and the current fabrication methods of related devices are introduced, together with their applications. Delving into the use of AI and AM technologies in droplet microfluidics, topics covered include AI-assisted simulations of droplet behavior, real-time tracking of droplets within microfluidic systems, and AM-fabrication of three-dimensional systems. The synergistic combination of AI and AM is expected to deepen the understanding of complex fluid dynamics and active matter behavior, expediting the transition toward fully digital microfluidic systems.