January 2025
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21 Reads
Historically, virtual impactors have been manufactured by CNC machining due to the tight dimensional tolerances and complex nozzle geometries required, which has resulted in both high per unit costs and design limitations. The reduced cost and increased availability of high resolution stereolithography (SLA) printing has enabled innovation of the design and manufacturing of virtual impactors. The new additive manufacturing design reported here enabled both the accelerating nozzle and receiving tube to be printed in a single unit for an estimated 1/10th the cost of traditional machining, while still maintaining an adequate nozzle size and geometry to provide a sharp cutoff curve. A dual-stage bio-aerosol concentrator has been designed at a nominal 400:1 concentration factor with an inlet flow rate of 120-L/min and an outlet concentrated flow rate of 0.30-L/min. To achieve this configuration, two virtual impactor stages in series are operated at the same aerodynamic diameter cutpoint. The first stage has 20 sets of nozzles in an opposing jet configuration, leading to a second stage with a single nozzle and receiving tube. The aerosol concentrator was evaluated experimentally with highly monodisperse oleic acid particles generated by a Flow Focusing Monodisperse Aerosol Generator. The experimental aerodynamic diameter cutpoint was 1.82-um with a geometric standard deviation of 1.16, which is considered a sharp separation cutoff curve. A total pressure drop of 3.9-kPa at the nominal inlet flow rate allowed a miniature high-speed blower with a power consumption of only 25-W to operate the bioaerosol concentrator.