Atomization dynamics of essential oils using twin-fluid atomizers with 3D-printed nozzles

This study investigates the atomization behavior of white tea essential oil a fragrance system predominantly composed of methyl dihydrojasmonate and Galaxolide; using a custom-built twin-fluid atomizer equipped with 3D-printed outer nozzles of twin-fluid atomizer. A laser diffraction particle size analyzer was employed to systematically evaluate the effects of three key factors on droplet size distribution (DSD) and volume median diameter (Dv50): gas inlet pressure, outer nozzle orifice diameters of a twin-fluid atomizer, and solvent formulation. Results show that increasing the inlet pressure significantly reduces Dv50 and improves droplet uniformity. By innovatively employing 3D-printed customized nozzles, this study systematically reveals key regulation mechanisms of atomization performance: the 1.2–1.3 mm aperture achieves an optimal balance between droplet uniformity and spatial coverage, while the unique performance of epoxy resin material at larger apertures suggests its interfacial properties may promote liquid film breakup. These findings provide new research perspectives and theoretical references for material selection and structural design in precision atomization devices.