Spray characteristics of an ultrasonic microdroplet generator with a continuously variable operating frequency

Droplet spraying is utilized in diverse industrial processes and biomedical applications, including nanomaterial synthesis, biomaterial handling, and inhalation drug delivery. Ultrasonic droplet generators transfer energy into bulk liquids using acoustic waves to disrupt the free liquid surface into fine microdroplets. We previously established a method combining ultrasonic actuation, resonant operation, and acoustic wave focusing for efficient spraying of various liquids (e.g., low surface tension fuels, high viscosity inks, and suspensions of biological cells). The microfabricated device comprises a piezoelectric transducer, sample reservoir, and an array of acoustic horn structures terminated by microscale orifices. Orifice size roughly dictates droplet diameter, and a fixed reservoir height prescribes specific device resonant frequencies of operation. Here, we incorporate a continuously variable liquid reservoir height for dynamic adjustment of operating parameters to improve spray efficiency in real-time and potentially tune the droplet size. Computational modeling predicts the system harmonic response for a range of reservoir heights from 0.5 to 3 mm (corresponding to operating frequencies from ∼500 kHz to 2.5 MHz). Nozzle arrays with 10, 20, and 40 μm orifices are evaluated for spray uniformity and stability of the active nozzles, using model predictions to explain the experimental observations.