Improving mixing efficiency of a polymer micromixer by use of a plastic shim divider

In this paper, a critical modification to a polymer based affordable split-and-recombination static micromixer is described. To evaluate the improvement, both the original and the modified design were carefully investigated using an experimental setup and numerical modeling approach. The structure of the micromixer was designed to take advantage of the process capabilities of both ultraprecision micromachining and microinjection molding process. Specifically, the original and the modified design were numerically simulated using commercial finite element method software ANSYS CFX to assist the re-designing of the micromixers. The simulation results have shown that both designs are capable of performing mixing while the modified design has a much improved performance. Mixing experiments with two different fluids were carried out using the original and the modified mixers again showed a significantly improved mixing uniformity by the latter. The measured mixing coefficient for the original design was 0.11, and for the improved design it was 0.065. The developed manufacturing process based on ultraprecision machining and microinjection molding processes for device fabrication has the advantage of high-dimensional precision, low cost and manufacturing flexibility.