Design and 3D printing of a Millifluidic Separation Device

This innovation presents a millifluidic separation device fabricated using two additive manufacturing processes, SLA (stereolithography) and FFF (fused filament fabrication), enabling the precise production of complex geometries tailored to specific separation requirements. The device features a spiral internal structure designed to optimize solid-liquid suspension separation based on the combined effects of inertial forces and secondary flow dynamics. Within the separator, particles  are distributed according to

their size and mass, with larger particles being directed toward the outer outlet, while smaller ones remail closer to the central flow stream. Experimental validation has confirmed that this separator can efficiently separate particles of different sizes from suspensions containing quartz sand, nanoparticles of

calcium carbonate, and talc. To evaluate the separation efficiency, laser diffraction, sieve analysis, and scanning electron microscopy (SEM) methods were used, with results confirming a clear distinction in particle size distribution between the separator’s outlets. Additionally, three different separator designs were tested, each optimized for specific flow conditions, and channel geometries, ensuring flexibility in adapting the device for various industrial applications. The potential applications of this innovative separator span across the chemical, pharmaceutical, and food industries, where precise solid particle separation is crucial for process optimization and enhanced production efficiency.