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.

In microfluidic systems, droplets undergo intricate deformations as they traverse flow-focusing junctions, posing a challenging task for accurate measurement, especially during short transit times. This study investigates the physical behavior of droplets within dense emulsions in diverse microchannel geometries, specifically focusing on the impact of varying opening angles within the primary channel and injection rates of fluid components. Employing a sophisticated droplet tracking tool based on deep-learning techniques, we analyze multiple frames from flow-focusing experiments to quantitatively characterize droplet deformation in terms of ratio between maximum width and height and propensity to form liquid with hexagonal spatial arrangement. Our findings reveal the existence of an optimal opening angle where shape deformations are minimal and hexagonal arrangement is maximal. Variations of fluid injection rates are also found to affect size and packing fraction of the emulsion in the exit channel. This paper offers insight into deformations, size, and structure of fluid emulsions relative to microchannel geometry and other flow-related parameters captured through machine learning, with potential implications for the design of microchips utilized in cellular transport and tissue engineering applications.

We introduce a two-step, fully reversible process designed to project the outer shape of a generic droplet onto a lower-dimensional space. The initial step involves representing the droplet's shape as a Fourier series. Subsequently, the Fourier coefficients are reduced to lower-dimensional vectors by using autoencoder models. The exploitation of the domain knowledge of the droplet shapes allows us to map generic droplet shapes to just two-dimensional (2D) space in contrast to previous direct methods involving autoencoders that could map it on minimum eight-dimensional (8D) space. This six-dimensional (6D) reduction in the dimensionality of the droplet's description opens new possibilities for applications, such as automated droplet generation via reinforcement learning, the analysis of droplet shape evolution dynamics, and the prediction of droplet breakup. Our findings underscore the benefits of incorporating domain knowledge into autoencoder models, highlighting the potential for increased accuracy in various other scientific disciplines.

Tracking droplets in microfluidics is a challenging task. The difficulty arises in choosing a tool to analyze general microfluidic videos to infer physical quantities. The state-of-the-art object detector algorithm You Only Look Once (YOLO) and the object tracking algorithm Simple Online and Realtime Tracking with a Deep Association Metric (DeepSORT) are customizable for droplet identification and tracking. The customization includes training YOLO and DeepSORT networks to identify and track the objects of interest. We trained several YOLOv5 and YOLOv7 models and the DeepSORT network for droplet identification and tracking from microfluidic experimental videos. We compare the performance of the droplet tracking applications with YOLOv5 and YOLOv7 in terms of training time and time to analyze a given video across various hardware configurations. Despite the latest YOLOv7 being 10% faster, the real-time tracking is only achieved by lighter YOLO models on RTX 3070 Ti GPU machine due to additional significant droplet tracking costs arising from the DeepSORT algorithm. This work is a benchmark study for the YOLOv5 and YOLOv7 networks with DeepSORT in terms of the training time and inference time for a custom dataset of microfluidic droplets.