Agglomeration of particles by a converging ultrasound field and their quantitative assessments

•A model to determine the ultrasound attenuation in multi-particle suspensions.•The transition in the particles from clustering at the organized nodal arrays to agglomerating along wave propagating directions under the BAW fields.•Quantitative assessments of the acoustically forming products.•Conditions and parametric suggestions of particles in forming the organized nodal arrays or agglomeration populations have been concluded and verified by experiments statistically. The acoustic radiation force resulting from acoustic waves have been extensively studied for the contact-free generation of organized patterning arrays. The precise arrangement of microscopic objects clustered at the pressure nodes is critical to the development of functional structures and patterned surfaces. However, the size of the clusters is restricted by the saturation limit of the acoustic nodes. Here, we present a bulk acoustic wave (BAW) platform, which employs a two-dimensional acoustic wave to propel particles of various sizes. Experimentally, when particles are large, significant acoustic energy is scattered and partly absorbed by the matched layers in front of the sensors. The acoustic radiation force from a convergent acoustic pressure field agglomerates the large polystyrene (PS) particles towards the central region instead of the pressure nodes. The parametric analysis has been performed to assess the transition in the particles from clustering at the organized nodal arrays to agglomerating in the central region, which is a function of particle size, particle concentration, and load voltage. Statistically, the particles can agglomerate with a cluster ratio greater than 70%, and this ratio can be improved by increasing the load power/voltage supplied to the transducers. With its ability to perform biocompatible, label-free, and contact-free self-assembly, this concept offers a new possibility in the fabrication of colloidal layers, the recreation of tissue microstructure, the development of organoid spheroid cultures, the migration of microorganisms, and the assembly of bioprinting materials.