Two-step design protocol for patterned groove micromixers

[Display omitted] ► New design protocol for patterned groove micromixers is presented. ► The protocol is easily applied in the micromixer design stage. ► Fewer grooves and shorter mixing length is needed compared to established designs. ► Favorable one-groove geometry depends on Reynolds number. ► Micromixer design is suitable to be produced with non-silicon technologies. Micromixers are essential components of microreactor technology. In this paper, a simple two-step design protocol for patterned groove micromixers based on numerical simulations is presented. In the first step, one groove of the staggered herringbone micromixer (SHM) is designed based on the average magnitude of transversal velocity vAVGyz at the end of the groove. In the second step, different configurations of six grooves are investigated. A slightly better mixing is achieved compared to the established SHM and significantly fewer grooves are needed. Due to fewer grooves and rounded groove corners, the new design is easier to be produced by microengineering technologies (MET). Additionally, good mixing was also achieved with a modified slanted groove micromixer (SGM) configuration with the largest rounding radius at the edges. A SGM prototype was machined by micro EDM milling. The simulation results were experimentally verified with flow visualization and a good agreement was observed. The presented protocol vastly reduces the number of optimal patterned groove geometry configuration candidates to be evaluated; it is simple and effective for practical applications.