3D printing and artificial intelligence tools for droplet microfluidics: Advances in the generation and analysis of emulsions.

This article provides a comprehensive review of recent advances in droplet microfluidics, focusing on the integration of artificial intelligence (AI) and additive manufacturing (AM) technologies to address current challenges in device design, fabrication, and droplet analysis. It details the fundamental physical mechanisms governing multiphase flows and droplet generation, summarizes conventional and emerging fabrication methods—including microfabrication, micromilling, laser micromachining, soft lithography, modular assembly, and various 3D printing techniques—and highlights applications spanning nanomaterials synthesis, optics, drug delivery, regenerative medicine, and more. The review emphasizes how AI, particularly machine learning models and physics-informed neural networks, enhances the prediction, classification, and real-time tracking of droplet behaviors, while AM enables the creation of complex, three-dimensional, and multi-material microfluidic devices with improved functionality and scalability. The convergence of AI and AM is presented as a promising pathway toward fully automated, intelligent microfluidic platforms capable of advancing research and industrial applications in diverse scientific fields.