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Although many geometries exist, consistent comparison across dimensions, fabrication methods, and evaluation techniques remains challenging. In this study, we present a comparative analysis of six micromixer designs, focusing on mixing efficiency, pressure drop, shear stress, and the energy-dissipation rate. The devices were fabricated using high-definition 3D printing and studied experimentally and with high-resolution computational fluid dynamics (CFD) simulations. Tests covered a wide Reynolds-number range (Re\u2009=\u20090.1\u2013200). At both ends of this range, most designs achieved adequate mixing. The greatest disparities emerged in the intermediate regime (Re\u2009=\u20091\u201350), with the Kenics geometry outperforming all other designs. Our grid-optimized CFD results matched experimental trends and quantified local shear and energy-dissipation rates. Live\/dead assays using an industrially relevant Chinese hamster ovary (CHO) cell line showed unchanged viability immediately after mixing and during subsequent cultivation. By combining experimentally validated CFD predictions, systematic grid-optimized assessment, and biological validation within a single framework, this study establishes a consistent basis for comparing micromixer designs and selecting those that match desired combinations of mixing performance, pressure drop, volume, shear stress, and the energy-dissipation rate.<\/jats:p>","DOI":"10.1038\/s41598-026-68945-1","type":"journal-article","created":{"date-parts":[[2026,8,28]],"date-time":"2026-08-28T18:03:06Z","timestamp":1787940186000},"update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Comparative numerical and experimental evaluation of 3D-printed micromixers for biotechnological applications"],"prefix":"10.1038","volume":"16","author":[{"ORCID":"https:\/\/orcid.org\/0009-0008-2677-238X","authenticated-orcid":false,"given":"Michael","family":"Mengele","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0009-0006-5349-2266","authenticated-orcid":false,"given":"Josef","family":"Z\u00fcrn","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-1962-5724","authenticated-orcid":false,"given":"Tanja","family":"Lochner","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0009-0008-7928-737X","authenticated-orcid":false,"given":"Ursula","family":"Wei\u00df","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-6107-9806","authenticated-orcid":false,"given":"Malte A.","family":"Peter","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-7008-1673","authenticated-orcid":false,"given":"Janina","family":"Bahnemann","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-3694-0008","authenticated-orcid":false,"given":"Christopher","family":"Heuer","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"297","published-online":{"date-parts":[[2026,8,28]]},"reference":[{"key":"68945_CR1","doi-asserted-by":"crossref","unstructured":"Ortseifen, V., Viefhues, M., Wobbe, L. & Gr\u00fcnberger, A. 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