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Droplet microfluidics is an important branch of microfluidic chip technology. It generates nanoliter‑ to picoliter‑sized droplets as independent micro‑reactors through two‑phase flow. Each droplet acts as a separate reaction vessel, offering high throughput, low consumption, and high sensitivity. Droplet generation on microfluidic chips is fast, highly uniform, and tunable in size, and has been widely applied in single‑cell analysis, digital PCR, drug screening, materials synthesis, and many other fields.
However, one issue has long plagued the industry – droplet fusion.
1. Fusion – the “roadblock” for droplet applications
Due to thermodynamic instability, droplets are highly prone to coalescence during generation, transport, and manipulation. When two independent droplets merge into one, it leads to uncontrolled size, cross‑talk between reactions, and invalidated data – for experiments that rely on droplets as isolated micro‑reactors, this is almost a fatal problem.
In traditional chip designs, fluid inlets and outlets are often arranged vertically. Such structures tend to cause flow disturbances when connecting tubing, exacerbating droplet collisions and coalescence. This seemingly simple issue has been a key bottleneck limiting the transition of droplet microfluidics from laboratory research to industrial production.
2. Tackling the root cause at the structural level
Suzhou Wenhao Microfluidic Technology Co., Ltd. has developed a systematic solution to this pain point, addressing it from two dimensions: chip architecture and fixture design.
First, the chip structure. The standard droplet generation chip is made of glass and features T‑junction and flow‑focusing geometries. These two designs are the most mature and mainstream approaches for droplet generation – the T‑junction uses the shear force of the continuous phase to “cut” droplets from the dispersed phase; the flow‑focusing employs symmetrical squeezing from both sides to break the dispersed phase at the constriction. Together, they cover the vast majority of droplet generation scenarios.
The more critical innovation lies in the fluid ports. While traditional chips mostly use vertical inlets/outlets, Wenhao’s chip adopts side‑entry ports. Do not underestimate this change – the side‑entry design, paired with a specially developed horizontal fixture, uses an integrated gasket structure to connect under pressure to the chip’s side ports. Liquids are introduced from the side and droplets are exported from the side, resulting in a smoother flow path and completely avoiding the disturbances and fusion issues caused by vertical port connections.
3. More than just “anti‑fusion” – it’s also “user‑friendly”
Solving fusion is only the foundation. In real research and industrial production, a chip’s usability also depends on flexibility, adaptability, and durability. Wenhao’s single‑emulsion standard chip and horizontal fixture excel in the following aspects:
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Flexible choice of chip structure and dimensions – customised to specific experimental needs, not limited to fixed specifications.
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Chip length adjustable from 22.5 to 120.0 mm – covering a wide range of applications from compact to long‑path designs, with high integration capability.
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Up to 8 fluid ports on the fixture – complex experiments often require multiple reagent inlets; the 8‑port configuration meets the demands of most intricate droplet preparation protocols.
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Pressure resistance exceeding 30 bar – the tight seal between chip and fixture allows high‑pressure operation.
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Small dead volume – minimal sample and reagent waste, which is especially beneficial for costly reagents.
In addition, the glass material itself offers smooth channel surfaces, a wide temperature and pressure tolerance, excellent chemical stability and biocompatibility, and superior optical properties – making it highly suitable for droplet generation and observation.
4. Beyond single emulsions
It is worth mentioning that Wenhao provides a complete suite of solutions in the droplet microfluidics field. In addition to single‑emulsion standard chips, we also offer double‑emulsion generation chips, droplet mass‑production equipment, and more. Our droplet generation chips cover T‑junction, flow‑focusing, co‑flow, and other geometries, with materials including glass, PDMS, PMMA, capillary tubes, and others. From laboratory‑scale R&D to industrial‑scale production, we have corresponding products and solutions.
5. A rapidly growing market
The market demand for droplet generation chips is also rising quickly. According to market research reports, the global droplet generation chip market was valued at approximately USD 156 million in 2025 and is projected to grow to USD 170 million in 2026, with a compound annual growth rate (CAGR) of 6.38%. The global microfluidic chip solutions market reached USD 2.56 billion in 2025 and is expected to reach USD 2.81 billion in 2026, representing a CAGR of 11.46%. Droplet microfluidics is moving from academic research into broader industrial applications.
The promise of droplet microfluidics is beyond doubt, but only by solving the fundamental issue of droplet fusion can its full potential be unleashed. Wenhao’s single‑emulsion standard chip and horizontal fixture address this from the structural design – replacing vertical ports with side‑entry ports, and ensuring sealing and stability with a high‑precision fixture. These seemingly straightforward improvements tackle a genuine industry pain point.
If you are also working on droplet microfluidics research or industrialisation, we welcome discussions and exchanges.
Suzhou Wenhao Microfluidic Technology Co., Ltd. – committed to providing complete products and solutions in the microfluidics field.
