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Microchannels

Microchannels are fluidic passages with cross-sectional dimensions in the micrometer to sub-millimeter range, typically tens to hundreds of micrometers in hydraulic diameter. They enable confinement and precise handling of small fluid volumes, and their high surface-to-volume ratio enhances heat and mass transfer relative to macro channels. In most microchannels, flow is laminar (low Reynolds number) and driven by pressure differences or electrokinetic effects.

Common geometries include rectangular and circular cross-sections, with straight, serpentine, or folded layouts to maximize residence

Fluid behavior in microchannels depends on fluid properties. Many applications use Newtonian liquids, while biofluids and

Applications span microfluidic labs-on-a-chip, chemical synthesis in microreactors, analytical devices, and cooling of microelectronics and electronics.

Key design considerations include pressure drop, thermal performance, chemical compatibility, and clogging or fouling due to

Performance metrics commonly used are pressure drop, Nusselt number for heat transfer, and a mixing or reaction

time
or
compactness.
Materials
range
from
silicon
and
glass
to
polymers
such
as
polydimethylsiloxane
(PDMS)
and
cyclic
olefin
copolymer
(COC);
metal
channels
are
also
used
in
some
applications.
Fabrication
methods
include
soft
lithography,
MEMS-based
etching,
laser
micromachining,
micro-milling,
and
bonding/lamination
techniques.
polymers
may
be
non-Newtonian.
Wall
effects
and
electrokinetic
phenomena
(electroosmosis
and
electrophoresis)
can
drive
flow
without
mechanical
pumps.
The
high
surface
area
fosters
rapid
heat
transfer,
but
mixing
is
limited
under
purely
laminar
conditions
and
often
requires
passive
or
active
strategies.
In
cooling,
microchannels
increase
heat
transfer
coefficients
and
enable
compact
liquid
cooling
systems.
In
biology
and
chemistry,
they
enable
controlled
reactions,
cell
manipulation,
and
sensor
integration.
deposits.
Bubble
formation
and
removal
are
practical
concerns.
Tolerances,
surface
roughness,
and
bonding
integrity
influence
reliability,
especially
in
modular
microfluidic
systems.
yield
index
for
microreactors.
Ongoing
research
seeks
to
improve
flow
control,
mixing
efficiency,
and
integration
with
sensors
and
actuators.