One step formation of controllable complex emulsions: from functional particles to simultaneous encapsulation of hydrophilic and hydrophobic agents into desired position

Concentric Capillary Microfluidic Devices Designed for Robust Production of Multiple-Emulsion Droplets

Multiple emulsions are used as templates for producing functional microcapsules due to their unique core-shell geometry. Employing glass capillary devices with coaxial channels has proven effective in creating uniform multiple-emulsion droplets. However, the use of partially miscible fluids, crucial for microcapsule production, often results in clogging and disrupts the stability of these devices. Here, we introduce innovative capillary microfluidic devices with concentric capillary channels, specifically designed to optimize the production of multiple-emulsion droplets while mitigating issues of precipitation and clogging. The key aspect of these devices is their configuration of two or three concentrically aligned capillaries, which form separate, coaxial microchannels for fluid injection. This unique alignment, achieved through rotational adjustments that leverage the natural off-center positioning of tapered capillaries, facilitates the simultaneous coaxial injection of various fluids into a droplet-forming junction, significantly reducing fluid contact before emulsification. The devices, featuring double and triple concentric capillary channels, consistently produce highly uniform double-, triple-, and quadruple-emulsion droplets with precisely controlled diameters and layer thicknesses. The minimal contact between fluids prior to emulsification in these devices broadens the usable range of fluid combinations, heralding new possibilities in microcapsule development for pharmaceutical and cosmetic applications.

Injectable thermogel constructed from self-assembled polyurethane micelle networks for 3D cell culture and wound treatment

Injectable hydrogels have attracted significant interest in the biomedical field due to their minimal invasiveness and accommodation of intricate scenes. Herein, we developed an injectable polyurethane-based thermogel platform by modulating the hydrophilic-hydrophobic balance of the segmented components with pendant PEG. The thermogelling behavior is achieved by a combination of the bridging from the hydrophilic PEG and the percolated network from the hydrophobic micelle core. Firstly, the thermogelation mechanism of this system was demonstrated by both DPD simulation and experimental investigation. The gelling temperature could be modulated by varying the solid content, the component of soft segments, and the length of the pendant PEG. We further applied 3D printing technology to prepare personalized hydrogel structures. This integration highlights the adaptability of our thermogel for fabricating complex and patient-specific constructs, presenting a significant advance in the field of regenerative medicine and tissue engineering. Subsequently, in vitro cell experiments demonstrated that the thermogel had good cell compatibility and could promote the proliferation and migration of L929 cells. Impressively, A549 cells could be expediently in situ parceled in the thermogel for three-dimensional cultivation and gain lifeful 3D cell spheres after 7 days. Further, in vivo experiments demonstrated that the thermogel could promote wound healing with the regeneration of capillaries and hair follicles. Ultimately, our study demonstrates the potential of hydrogels to prepare personalized hydrogel structures via 3D printing technology, offering innovative solutions for complex biomedical applications. This work not only provides a fresh perspective for the design of injectable thermogels but also offers a promising avenue to develop thermoresponsive waterborne polyurethane for various medical applications.

Dynamic Photonic Janus Colloids with Axially Stacked Structural Layers

Diblock copolymer (dBCP) particles capable of dynamic shape and color changes have gained significant attention due to their versatility in programmable shapes and intricate nanostructures. However, their application in photonic systems remains limited due to challenges in achieving a sufficient number of defect-free photonic layers over a tens-of-micrometer scale. In this study, we present a pioneering demonstration of photonic dBCP particles featuring over 300 axially stacked photonic layers with responsive color- and shape-transforming capabilities. Our approach leverages the complex interplay between the macrophase separation of multiple incompatible components and the microphase separation of dBCP from solvent-evaporative microemulsions. Specifically, continuous phase separation of silicone oil from polystyrene-block-poly(2-vinylpyridine) (PS-b-P2VP), triggered by solvent evaporation, promotes the anisotropic growth of PS-b-P2VP layers. This results in the formation of Janus colloids, where an oil droplet merges with a nanostructured polymer cone and lamellar structures align along the long axis of the cone. We highlight the capability to precisely adjust the particle morphology and the corresponding orientation, dispersion, and structural color window by modulating both the molecular weight of PS-b-P2VP and the volume ratio between PS-b-P2VP and silicone oil. Furthermore, reversible swelling/deswelling of photonic colloids is visualized and correlated with their structural colors. Finally, we demonstrate the potential of this study by presenting a multicolor-patterned array of photonic colloids, highlighting the possibilities for applications in smart photonic ink and devices.

Double Emulsion Droplets as a Plausible Step to Fatty Acid Protocells

It is assumed that life originated on the Earth from vesicles made of fatty acids. These amphiphiles are the simplest chemicals, which can be present in the prebiotic soup, capable of self-assembling into compartments mimicking modern cells. Production of fatty acid vesicles is widely studied, as their growing and division. However, how prebiotic chemicals require to further yield living cells encapsulated within protocells remains unclear. Here, one suggests a scenario based on recent studies, which shows that phospholipid vesicles can form from double emulsions affording facile encapsulation of cargos. In these works, water-in-oil-in-water droplets are produced by microfluidics, having dispersed lipids in the oil. Dewetting of the oil droplet leaves the internal aqueous droplet covered by a lipid bilayer, entrapping cargos. In this review, formation of fatty acid protocells is briefly reviewed, together with the procedure for preparing double emulsions and vesicles from double emulsion and finally, it is proposed that double emulsion droplets formed in the deep ocean where undersea volcano expulsed materials, with fatty acids (under their carboxylic form) and alkanols as the oily phase, entrapping hydrosoluble prebiotic chemicals in a double emulsion droplet core. Once formed, double emulsion droplets can move up to the surface, where an increase of pH, variation of pressure and/or temperature may have allowed dewetting of the oily droplet, leaving a fatty acid vesicular protocell with encapsulated prebiotic materials.

One step generation of single-core double emulsions from polymer-osmose-induced aqueous phase separation in polar oil droplets

Water-in-oil-in-water emulsions (W/O/W) are aqueous droplet(s) embedded within oil droplets dispersed in a continuous water phase. They are attracting interest due to their possible applications from cosmetic to food science since both hydrosoluble and liposoluble cargos can be encapsulated within. They are generally prepared using a one-step or a two-step method, phase inversion and also via spontaneous emulsification. Here, we describe a general and simple one-step method based on hydrophilic polymers dispersed in polar oils to generate osmose-induced diffusion of water into oil droplets, forming polymer-rich aqueous droplets inside the oil droplets. Polyethylene glycol, but also other hydrophilic polymers (branched polyethylene imine or polyvinyl pyrrolidone) were successfully dispersed in 1-octanol or other polar oils (oleic acid or tributyrin) to produce an O/W emulsion that spontaneously transformed into a W1/O/W2 emulsion, with the inner aqueous droplet (W1) only containing the hydrophilic polymer initially dispersed in oil. By combining single drop experiments, with macroscopic viscosity measurements, we demonstrated that the double emulsion resulted of water diffusion, which amplitude could be adjusted by the polymer concentration. The production of high internal phase emulsions was also achieved, together with a pH-induced transition from multiple to single core double emulsion. We expect this new method for producing double emulsions to find applications in domains of microencapsulation and materials chemistry.

Microfluidics in drug delivery: review of methods and applications

Microfluidics technology has emerged as a promising methodology for the fabrication of a wide variety of advanced drug delivery systems. Owing to its ability for accurate handling and processing of small quantities of fluidics as well as immense control over physicochemical properties of fabricated micro and nanoparticles (NPs), microfluidic technology has significantly improved the pharmacokinetics and pharmacodynamics of drugs. This emerging technology has offered numerous advantages over the conventional drug delivery methods for fabricating of a variety of micro and nanocarriers for poorly soluble drugs. In addition, a microfluidic system can be designed for targeted drug delivery aiming to increase the local bioavailability of drugs. This review spots the light on the recent advances made in the area of microfluidics including various methods of fabrication of drug carriers, their characterization, and unique features. Furthermore, applications of microfluidic technology for the robust fabrication and development of drug delivery systems, the existing challenges associated with conventional fabrication methodologies as well as the proposed solutions offered by microfluidic technology have been discussed in details.HighlightsMicrofluidic technology has revolutionized fabrication of tunable micro and nanocarriers.Microfluidic platforms offer several advantages over the conventional fabrication methods.Microfluidic devices hold great promise in controlling the physicochemical features of fabricated drug carriers.Micro and nanocarriers with controllable release kinetics and site-targeting efficiency can be fabricated.Drug carriers fabricated by microfluidic technology exhibited improved pharmacokinetic and pharmacodynamic profiles.

Recent progress in the synthesis of all-aqueous two-phase droplets using microfluidic approaches

An aqueous two-phase system (ATPS) is a system with liquid-liquid phase separation and shows great potential for the extraction, separation, purification, and enrichment of proteins, membranes, viruses, enzymes, nucleic acids, and other biomolecules because of its simplicity, biocompatibility, and wide applicability [1-4]. The clear aqueous-aqueous interface of ATPSs is highly advantageous for their implementation, therefore making ATPSs a green alternative approach to replace conventional emulsion systems, such as water-in-oil droplets. All aqueous emulsions (water-in-water, w-in-w) hold great promise in the biomedical field as glucose sensors [5] and promising carriers for the encapsulation and release of various biomolecules and nonbiomolecules [6-10]. However, the ultralow interfacial tension between the two phases is a hurdle in generating w-in-w emulsion droplets. In the past, bulk emulsification and electrospray techniques were employed for the generation of w-in-w emulsion droplets and the fabrication of microparticles and microcapsules in the later stage. Bulk emulsification is a simple and low-cost technique; however, it generates polydisperse w-in-w emulsion droplets. Another technique, electrospray, involves easy experimental setups that can generate monodisperse but nonspherical w-in-w emulsion droplets. In comparison, microfluidic platforms provide monodisperse w-in-w emulsion droplets with spherical shapes, deal with the small volumes of solutions and short reaction times and achieve portability and versatility in their design through rapid prototyping. Owing to several advantages, microfluidic approaches have recently been introduced. To date, several different strategies have been explored to generate w-in-w emulsions and multiple w-in-w emulsions and to fabricate microparticles and microcapsules using conventional microfluidic devices. Although a few review articles on ATPSs emulsions have been published in the past, to date, few reviews have exclusively focused on the evolution of microfluidic-based ATPS droplets. The present review begins with a brief discussion of the history of ATPSs and their fundamentals, which is followed by an account chronicling the integration of microfluidic devices with ATPSs to generate w-in-w emulsion droplets. Furthermore, the stabilization strategies of w-in-w emulsion droplets and microfluidic fabrication of microparticles and microcapsules for modern applications, such as biomolecule encapsulation and spheroid construction, are discussed in detail in this review. We believe that the present review will provide useful information to not only new entrants in the microfluidic community wanting to appreciate the findings of the field but also existing researchers wanting to keep themselves updated on progress in the field.

Flow lithography for structured microparticles: fundamentals, methods and applications

Structured microparticles, with unique shapes, customizable sizes, multiple materials, and spatially-defined chemistries, are leading the way for emerging 'lab on a particle' technologies. These microparticles with engineered designs find applications in multiplexed diagnostics, drug delivery, single-cell secretion assays, single-molecule detection assays, high throughput cytometry, micro-robotics, self-assembly, and tissue engineering. In this article we review state-of-the-art particle manufacturing technologies based on flow-assisted photolithography performed inside microfluidic channels. Important physicochemical concepts are discussed to provide a basis for understanding the fabrication technologies. These photolithography technologies are compared based on the structural as well as compositional complexity of the fabricated particles. Particles are categorized, from 1D to 3D particles, based on the number of dimensions that can be independently controlled during the fabrication process. After discussing the advantages of the individual techniques, important applications of the fabricated particles are reviewed. Lastly, a future perspective is provided with potential directions to improve the throughput of particle fabrication, realize new particle shapes, measure particles in an automated manner, and adopt the 'lab on a particle' technologies to other areas of research.

Centrifugally spun alginate-poly(lactic acid) microbeads: A promising carrier for drug delivery and tissue engineering

A facile and high yield centrifugal spinning technique known as Forcespinning® (FS) was used to develop unique microstructures consisting of PLA microbeads along alginate fibers. Morphological variation and structural features appeared in the field-emission scanning electron micrographs for the PLA-alginate composites and dried PLA-alginate films from precursor emulsions at constant PLA and varied alginate contents. Shrunk and deflated microbeads were observed for composites whilst spherical beads were evident for the PLA control. Furthermore, PLA was found surrounding the alginate when the alginate was present at 0.24 wt% or lower, while alginate (mushroom-like structures), were seen protruding through the PLA layer at ≥0.34 wt% alginate. Rheological characterization of the composite emulsions revealed that the filler (alginate) provided shear thinning properties including pseudoplasticity, desirable for printing and other related applications in contrast to the Newtonian flow shown by the PLA control. Along with infra-red spectroscopy, the nanocomposites were further characterized using thermal gravimetry and differential scanning calorimetry featuring reversible events influenced by heat capacity and irreversible kinetic/thermodynamic counterparts. The work provides a comprehensive investigation of biocompatible networks of PLA-alginate microbeads embedded in nano-sized fibers and the prospective application of these microbeads as a drug delivery system.

Janus Droplet Formation via Thermally Induced Phase Separation: A Numerical Model with Diffusion and Convection

Microscale Janus particles have versatile potential applications in many physical and biomedical fields, such as microsensor, micromotor, and drug delivery. Here, we present a phase-field approach of multicomponent and multiphase to investigate the Janus droplet formation via thermally induced phase separation. The crucial kinetics for the formation of Janus droplets consisting of two polymer species and a solvent component via an interplay of both diffusion and convection is considered in the Cahn-Hilliard-Navier-Stokes equation. The simulation results of the phase-field model show that unequal interfacial tensions between the two polymer species and the solvent result in asymmetric phase separation in the formation process of Janus droplets. This asymmetric phase separation plays a vital role in the establishment of the so-called core-shell structure that has been observed in previous experiments. By varying the droplet size, the surface tension, and the molecular interaction between the polymer species, several novel droplet morphologies are predicted in the development process of Janus droplets. Moreover, we stress that the hydrodynamics should be reckoned as a non-negligible mechanism that not only accelerates the Janus droplet evolution but also has great impacts on the coarsening and coalescence of the Janus droplets.

Construction and Application of in vitro Alveolar Models Based on 3D Printing Technology

Increasing lung diseases, mutating coronaviruses, and the development of new compounds urgently require biomimetic in vitro lung models for lung pathology, toxicology, and pharmacology. The current construction strategies for lung models mainly include animal models, 2D cell culture, lung-on-a-chip, and lung organoids. However, current models face difficulties in reproducing in vivo-like alveolar size and vesicle-like structures, and are unable to contain multiple cell types. In this study, a strategy for constructing alveolar models based on degradable hydrogel microspheres is proposed. Hydrogel microspheres, 200–250 µm in diameter, were prepared using a self-developed printing technique driven by alternating viscous and inertial forces. Microcapsules were further constructed using a coacervation-based layer-by-layer technique and core liquefaction. Three types of cells were inoculated and co-cultured on hydrogel capsules based on optimized microcapsule surface treatment strategies. Finally, an in vitro three-dimensional endothelial alveolar model with a multicellular composition and vesicle-like structure with a diameter of approximately 230 µm was successfully constructed. Cells in the constructed alveolar model maintained a high survival rate. The LD₅₀ values of glutaraldehyde based on the constructed models were in good agreement with the reference values, validating the potential of the model for future toxicant and drug detection.

Recent advances in acoustic microfluidics and its exemplary applications

Acoustic-based microfluidics has been widely used in recent years for fundamental research due to its simple device design, biocompatibility, and contactless operation. In this article, the basic theory, typical devices, and technical applications of acoustic microfluidics technology are summarized. First, the theory of acoustic microfluidics is introduced from the classification of acoustic waves, acoustic radiation force, and streaming flow. Then, various applications of acoustic microfluidics including sorting, mixing, atomization, trapping, patterning, and acoustothermal heating are reviewed. Finally, the development trends of acoustic microfluidics in the future were summarized and looked forward to.

Simple One-Step and Rapid Patterning of PDMS Microfluidic Device Wettability for PDMS Shell Production

Double emulsion (DE) droplets with controlled size and internal structure are a promising platform for biological analysis, chemical synthesis, and drug delivery systems. However, to further “democratize” their application, new methods that enable simple and precise spatial patterning of the surface wettability of droplet-generating microfluidic devices are still needed. Here, by leveraging the increase in hydrophilicity of polydimethylsiloxane (PDMS) due to the plasma-treatment used to permanently bond to glass, we developed a one-step method to selectively pattern the wettability of PDMS microfluidic devices for DE generation. Our results show that both Aquapel-treated and 1H,1H,2H,2H-Perfluorodecyltriethoxysilan (PFDTES)-treated devices are functionally showing the generality of our method. With the resulting microfluidic devices, both water-in-oil-in-water (w/o/w) and oil-in-water-in-oil (o/w/o) DE droplets can be produced. Using a PDMS mixture containing cross-linking agents, we formed PDMS microcapsules by solidifying the shell layer of water-in-PDMS-in-water DE droplets. We also characterize the morphological properties of the generated droplets/microcapsules. We anticipate the method developed in this work could be used in a broad range of applications of DE droplets.

Gradient Printing Alginate Herero Gel Microspheres for Three-Dimensional Cell Culture

Hydrogel microspheres are widely used in tissue engineering, such as 3D cell culture and injection therapy, and among which, heterogeneous microspheres are drawing much attention as a promising tool to carry multiple cell types in separated phases. However, it is still a big challenge to fabricate heterogeneous gel microspheres with excellent resolution and different material components in limited sizes. Here, we developed a multi-channel dynamic micromixer, which can use active mechanical mixing to achieve rapid mixing with multi-component materials and extrude the homogenized material. By changing the flow rate ratio of the solutions of the two components and by rapidly mixing in the micromixer, real-time concentration change of the mixed material at the outlet could be monitored in a process so-called “gradient printing”. By studying the mixing efficiency of the micromixer, its size and process parameters were optimized. Using the novel dynamic gradient printing method, the composition of the hydrogel microspheres can be distributed in any proportion and alginate heterogeneous gel microspheres with adjustable cell concentration were fabricated. The effects of cell concentration on cell viability and proliferation ability under three-dimensional culture conditions were also studied. The results showed that cells have very low death rate and can exchange substances within the microspheres. Due to the micromixing ability of the micromixers, the demand for biological reagents and materials such as cells, proteins, cytokines and other materials could be greatly reduced, which helps reduce the experimental cost and improve the feasibility of the method in practical use. The heterogeneous gel microsphere can be greatly valuable for research in various fields such as analytical chemistry, microarray, drug screening, and tissue culture.

Cell-Inspired Hydrogel Microcapsules with a Thin Oil Layer for Enhanced Retention of Highly Reactive Antioxidants

In nature, individual cells are compartmentalized by a membrane that protects the cellular elements from the surrounding environment while simultaneously equipped with an antioxidant defense system to alleviate the oxidative stress resulting from light, oxygen, moisture, and temperature. However, this mechanism has not been realized in cellular mimics to effectively encapsulate and retain highly reactive antioxidants. Here, we report cell-inspired hydrogel microcapsules with an interstitial oil layer prepared by utilizing triple emulsion drops as templates to achieve enhanced retention of antioxidants. We employ ionic gelation for the hydrogel shell to prevent exposure of the encapsulated antioxidants to free radicals typically generated during photopolymerization. The interstitial oil layer in the microcapsule serves as an stimulus-responsive diffusion barrier, enabling efficient encapsulation and retention of antioxidants by providing an adequate pH microenvironment until osmotic pressure is applied to release the cargo on-demand. Moreover, addition of a lipophilic reducing agent in the oil layer induces a complementary reaction with the antioxidant, similar to the nonenzymatic antioxidant defense system in cells, leading to enhanced retention of the antioxidant activity. Furthermore, we show the complete recovery and even further enhancement in antioxidant activity by lowering the storage temperature, which decreases the oxidation rate while retaining the complementary reaction with the lipophilic reducing agent.

Core-shell microparticles: From rational engineering to diverse applications

Core-shell microparticles, composed of solid, liquid, or gas bubbles surrounded by a protective shell, are gaining considerable attention as intelligent and versatile carriers that show great potential in biomedical fields. In this review, an overview is given of recent developments in design and applications of biodegradable core-shell systems. Several emerging methodologies including self-assembly, gas-shearing, and coaxial electrospray are discussed and microfluidics technology is emphasized in detail. Furthermore, the characteristics of core-shell microparticles in artificial cells, drug release and cell culture applications are discussed and the superiority of these advanced multi-core microparticles for the generation of artificial cells is highlighted. Finally, the respective developing orientations and limitations inherent to these systems are addressed. It is hoped that this review can inspire researchers to propel the development of this field with new ideas.

Microfluidics-Enabled Soft Manufacture of Materials with Tailorable Wettability

Microfluidics and wettability are interrelated and mutually reinforcing fields, experiencing synergistic growth. Surface wettability is paramount in regulating microfluidic flows for processing and manipulating fluids at the microscale. Microfluidics, in turn, has emerged as a versatile platform for tailoring the wettability of materials. We present a critical review on the microfluidics-enabled soft manufacture (MESM) of materials with well-controlled wettability and their multidisciplinary applications. Microfluidics provides a variety of liquid templates for engineering materials with exquisite composition and morphology, laying the foundation for precisely controlling the wettability. Depending on the degree of ordering, liquid templates are divided into individual droplets, one-dimensional (1D) arrays, and two-dimensional (2D) or three-dimensional (3D) assemblies for the modular fabrication of microparticles, microfibers, and monolithic porous materials, respectively. Future exploration of MESM will enrich the diversity of chemical composition and physical structure for wettability control and thus markedly broaden the application horizons across engineering, physics, chemistry, biology, and medicine. This review aims to systematize this emerging yet robust technology, with the hope of aiding the realization of its full potential.

Processing of fast-gelling hydrogel precursors in microfluidics by electrocoalescence of reactive species

Microscopic hydrogels, also referred to as microgels, find broad application in life and materials science. A well-established technique for fabricating uniform microgels is droplet microfluidics. Here, optimal mixing of hydrogel precursor components is crucial to yield homogeneous microgels with respect to their morphology, mechanics, and distribution of functional moieties. However, when processing premixed polymer precursors that are highly reactive, fast or even instantaneous gelation inside fluid reservoirs or the microchannels of the flow cell commonly occurs, leading to an increase of fluid viscosity over time, and thus exacerbating the intrinsic control over fluid flow rates, droplet and microgel uniformity, which are key selling points of microfluidics in material design. To address these challenges, we utilize microflow cells with integrated electrodes, which enable fast addition and mixing of hydrogel precursors on demand by means of emulsion droplet coalescence. Here, two populations of surfactant-stabilized aqueous droplets - the first containing the material basis of the microgel, and the second containing another gel-forming component (e.g., a crosslinker) are formed at two consecutive microchannel junctions and merged via temporary thin-film instability. Our approach provides the ability to process such hydrogel systems that are otherwise challenging to process into uniform droplets and microgels by conventional droplet microfluidics. To demonstrate its versatility, we fabricate microgels with uniform shape and composition using fast hydrogelation via thiol-Michael addition reaction or non-covalent self-assembly. Furthermore, we elucidate the limitations of electrocoalescence of reactive hydrogel precursors by processing sodium alginate, crosslinked by calcium-induced ionic interactions. For this instantaneous type of hydrogelation, electrocoalescence of alginate and calcium ions does not result in the formation of morphologically isotropic microgels. Instead, it enables the creation of anisotropic microgel morphologies with tunable shape, which have previously only been achieved by selective crosslinking of elaborate higher-order emulsions or by aqueous two-phase systems as microgel templates.

Microfluidic droplet-based functional materials for cell manipulation

Functional materials from the microfluidic-based droplet community are emerging as enabling tools for various applications in tissue engineering and cell biology. The innovative micro- and nano-scale materials with diverse sizes, shapes and components can be fabricated without the use of complicated devices, allowing unprecedented control over the cells that interact with them. Here, we review the current development of microfluidic-based droplet techniques for creation of functional materials (i.e., liquid droplet, microcapsule, and microparticle). We also describe their various applications for manipulating cell fate and function.

Perpendicular alignment of the phase-separated boundary in adhered polymer droplets

We investigated the effect of the adhered interface on the phase separation pattern using two or three adhered droplets containing a binary solution of poly(ethylene glycol) and gelatin. Under the experimental conditions, single domains of the gelatin-rich phase exhibited partial wetting to the droplet adhered interface (DAI) and nonadhered droplet surface. In the case of isolated spherical droplets, the location of the phase separation interface (PSI) of the domains was completely random owing to spatial symmetry. In the adhered droplets, the random orientation of the PSI was observed when the PSI did not contact the DAI. On the other hand, when the PSI contacted the DAI, the PSI was aligned perpendicular to the DAI. Frequency analysis showed that whether the PSI contacts the DAI is purely stochastic. However, the PSI alignment perpendicular to the DAI increases significantly with three adhered droplets, suggesting that the probability increases with increasing DAI area ratio. We explain this perpendicular pattern by the minimization of the interfacial energy and kinetics with a change in the wetting contact angle. These findings will facilitate the research on the phase separation of polymer solutions inside nonspherical micrometric spaces.

Emulsion Designer Using Microfluidic Three-Dimensional Droplet Printing in Droplet

Hierarchical emulsions are interesting for both scientific researches and practical applications. Hierarchical emulsions prepared by microfluidics require complicated device geometry and delicate control of flow rates. Here, a versatile method is developed to design hierarchical emulsions using microfluidic 3D droplet printing in droplet. The process of droplet printing in droplet mimics the dragonfly laying eggs and has advantages of easy processing and flexible design. To demonstrate the capability of the method, double emulsions and triple emulsions with tunable core number, core size, and core composition are prepared. The hierarchical emulsions are excellent templates for the developments of functional materials. Flattened crescent-moon-shaped particles are then fabricated using double emulsions printed in confined 2D space as templates. The particles are excellent delivery vehicles for 2D interfaces, which can load and transport cargos through a well-defined trajectory under external magnetic steering. Microfluidic 3D droplet printing in droplet provides a powerful platform with improved simplicity and flexibility for the design of hierarchical emulsions and functional materials.

Core-shell droplets and microcapsules formed through liquid-liquid phase separation of a colloid-polymer mixture

Microcapsules allow for the controlled containment, transport, and release of cargoes ranging from pharmaceuticals to fragrances. Given the interest from a variety of industries in microcapsules and other core-shell structures, a multitude of fabrication strategies exist. Here, we report on a method relying on a mixture of temperature-responsive microgel particles, poly(N-isopropylacrylamide) (pNIPAM), and a polymer which undergo fluid-fluid phase separation. At room temperature this mixture separates into colloid-rich (liquid) and colloid-poor (gas) fluids. By heating the sample above a critical temperature where the microgel particles shrink dramatically and develop a more deeply attractive interparticle potential, the droplets of the colloid-rich phase become gel-like. As the temperature is lowered back to room temperature, these droplets of gelled colloidal particles reliquefy and phase separation within the droplet occurs. This phase separation leads to colloid-poor droplets within the colloid-rich droplets surrounded by a continuous colloid-poor phase. The gas/liquid/gas all-aqueous double emulsion lasts only a few minutes before a majority of the inner droplets escape. However, the colloid-rich shell of the core-shell droplets can solidify with the addition of salt. That this method creates core-shell structures with a shell composed of stimuli-sensitive microgel colloidal particles using only aqueous components makes it attractive for encapsulating biological materials and making capsules that respond to changes in, for example, temperature, salt concentration, or pH.

Crosslinking Strategies for the Microfluidic Production of Microgels

This article provides a systematic review of the crosslinking strategies used to produce microgel particles in microfluidic chips. Various ionic crosslinking methods for the gelation of charged polymers are discussed, including external gelation via crosslinkers dissolved or dispersed in the oil phase; internal gelation methods using crosslinkers added to the dispersed phase in their non-active forms, such as chelating agents, photo-acid generators, sparingly soluble or slowly hydrolyzing compounds, and methods involving competitive ligand exchange; rapid mixing of polymer and crosslinking streams; and merging polymer and crosslinker droplets. Covalent crosslinking methods using enzymatic oxidation of modified biopolymers, photo-polymerization of crosslinkable monomers or polymers, and thiol-ene “click” reactions are also discussed, as well as methods based on the sol−gel transitions of stimuli responsive polymers triggered by pH or temperature change. In addition to homogeneous microgel particles, the production of structurally heterogeneous particles such as composite hydrogel particles entrapping droplet interface bilayers, core−shell particles, organoids, and Janus particles are also discussed. Microfluidics offers the ability to precisely tune the chemical composition, size, shape, surface morphology, and internal structure of microgels by bringing multiple fluid streams in contact in a highly controlled fashion using versatile channel geometries and flow configurations, and allowing for controlled crosslinking.

Spontaneous Wrinkle Formation on Hydrogel Surfaces Using Photoinitiator Diffusion from Oil-Water Interface

Patterning wrinkles on three-dimensional curved or enclosed surfaces can be challenging due to difficulties in application of uniform films and stresses on such structures. In this study, we demonstrate a simple one-step wrinkle-formation method on various hydrogel structures utilizing the oil-water interfaces. By diffusion of the photoinitiator from the oil phase to the prepolymer solution in water through the interface, a characteristic cross-linking gradient is set up in the hydrogel. Then, after photopolymerization, we observe diverse patterns of wrinkles upon changing the concentration of the hydrogel or photoinitiator. As the wrinkle formation via photoinitiator diffusion through the interface requires only UV exposure for polymerization, while taking advantage of the oil-water interfacial tension, wrinkles can be developed easily on various curved structures. In addition, we illustrate the formation of wrinkles on surfaces underneath another layer of polymer or on completely enclosed surfaces, which is difficult with conventional methods. We expect that our results will lead to production of novel microstructures and provide a platform for studying the morphogenesis of wrinkles found in nature such as in curved substrates and multilayers.

Monodisperse Selectively Permeable Hydrogel Capsules Made from Single Emulsion Drops

Capsules are often used to protect chemical and biological entities from the environment, to control the timing and location of their release, or to facilitate the collection of waste. Their performance depends on the thickness and composition of their shells, which can be closely controlled if capsules are made from double emulsion drops that are produced with microfluidics. However, the fabrication of such double emulsions is delicate, limiting throughput and increasing costs. Here, a fast, scalable method to produce monodisperse microcapsules possessing mechanically robust, thin, semipermeable hydrogel shells from single emulsion drops is introduced. This is achieved by selectively polymerizing reagents in close proximity to the drop surface to form a biocompatible 1.6 μm-thick hydrogel shell that encompasses a liquid core. The size-selective permeability of the shell enables the growth of living yeast and bacteria in their cores. Moreover, if capsules are loaded with adsorbents, they can repetitively remove waste products from water. The simplicity and robustness of the capsule fabrication makes the process scalable and cost effective. It has thus the potential to extend the use of calibrated capsules possessing well-defined dimensions to cost sensitive fields, including food, waste water treatment, or oil recovery.

Vapor-Induced Liquid Collection and Microfluidics on Superlyophilic Substrates

Liquid manipulation on solid surfaces has attracted a lot of attention for liquid collection and droplet-based microfluidics. However, manipulation strategies mainly depend on chemical modification and artificial structures. Here, we demonstrate a feasible and general strategy based on the self-shrinkage of the droplet induced via specific vapors to efficiently collect liquids and flexibly carry out droplet-based reactions. The vapor-induced self-shrinkage is driven by Marangoni flow originating from molecular adsorption and diffusion. Under a specific vapor environment, the self-shrinking droplet exhibits unique features including reversible responsiveness, high mobility, and autocoalescence. Accordingly, by building a specific vapor environment, the thin liquid films and random liquid films on superlyophilic substrates can be recovered with a collection rate of more than 95%. Moreover, the vapor system can be used to construct a high-efficiency chemical reaction device. The findings and profound understandings are significant for the development of the liquid collection and droplet-based microfluidics.

Surface-tension-induced double emulsion drops via phase separation of polymeric fluid confined in micromolds for capsule templates

We report a simple and rapid route to produce double emulsion drops by utilizing phase separation of the confined fluid in micromolds and surface-tension-induced drop formation. Specifically, we use cross-shaped micromolds containing prepolymer solution that phase-separates into two compartments upon addition of wetting fluid with separation agent (SA). Subsequently, Laplace pressure-driven flow allows it to form double emulsion drops without use of any surfactants and complex formulations of fluids. The size of each compartment in the emulsion drops can be controlled by tuning composition of the prepolymer solution and separation agent, making the double emulsion drops with varying shell thicknesses. The phase separation creates two compartments with different polarity (i.e. water-soluble and water-insoluble), enabling encapsulation of both hydrophilic and/-or hydrophobic cargoes in desired compartments depending on their solubility. In addition, we produce poly(N-isopropylacrylamide) (pNIPAm) hydrogel microcapsules by solidifying middle phase in the double emulsion drops; thus, hydrophilic large cargo loaded priorly in the core can be encapsulated within hydrogel shells. Finally, by taking advantage of hydrophilic-hydrophobic phase transition behavior of pNIPAm, we achieve encapsulation of small cargo via post-loading approach; the encapsulated cargo can be released by tuning temperature.

Designing the Morphology of Separated Phases in Multicomponent Liquid Mixtures

Phase separation of multicomponent liquid mixtures plays an integral part in many processes ranging from industry to cellular biology. In many cases the morphology of coexisting phases is crucially linked to the function of the separated mixture, yet it is unclear what determines the morphology when multiple phases are present. We developed a graph theory approach to predict the topology of coexisting phases from a given set of surface energies, enumerate all topologically distinct morphologies, and reverse engineer conditions for surface energies that produce the target morphology.

Functional reservoir microcapsules generated via microfluidic fabrication for long-term cardiovascular therapeutics

Cardiovascular disease is a chronic disease that leads to impaired cardiac function and requires long-term management to control its progression. Despite the importance of hydrogels for therapeutic applications, a contradiction between the size of a hydrogel and the amount of loaded drug has been encountered when using conventional fabrication methods. In this study, biocompatible reservoir microcapsules (diameter ∼100 μm) with a large liquid core and polymeric shell were fabricated via a one-step phase separation of poly(ethylene glycol)diacrylate (PEGDA) and dextran within pre-gel droplets through microfluidics. By controlling the process of phase separation, high drug-loading efficiency (∼80%) for long-term release (30 days) of vascular endothelial growth factor (VEGF) and platelet-derived growth factor (PDGF) was achieved. Drug molecules were dispersed within the liquid core at a concentration above saturation solubility for sustained delivery via regulation of the shells. Effective therapeutic enhancement of human umbilical vein endothelial cell (HUVEC) and umbilical artery smooth muscle cell (SMC) proliferation and tube formation in vitro promoted rapid cell proliferation and increased the number of migrated cells by ∼1.7 times. Moreover, in vivo blood vessel regeneration for cardiovascular control induced by sustained dual-drug (VEGF and PDGF) delivery to the rat heart was achieved, showing the effectiveness of long-term protein delivery in improving cardiac function and significantly reducing ventricular wall thickness and fibrosis of the infarct region. The ratio of heart tissue scarring was reduced to 11.2% after microcapsule treatment compared with 21.4% after saline treatment in the rat model. By using these reservoir microcapsules, similar sustained delivery of proteins, mRNAs and biologic drugs could be developed for the treatment of a range of long-term chronic diseases and regenerative medicine.

Kinetics of active water/ethanol Janus droplets

Droplets made of a water/ethanol mixture spontaneously self-propel in an oil/surfactant solution and, depending on the initial ethanol concentration at the time of production, may evolve in up to three stages. Upon self-propulsion the droplets absorb surfactant molecules during their continuous motion in the oily phase. In combination with the continuous loss of ethanol this mass exchange with the ambient phase may lead to a spontaneous phase separation of the water/ethanol mixture, and eventually to the formation of characteristic Janus droplets. Supported by experimental evidence, we propose a simple model that is able to explain the propulsion velocity and its scaling with the droplet radius in the last stage of the droplet evolution.

Complex emulsions for shape control based on mass transfer and phase separation

Complex emulsions are used to fabricate new morphologies of multiple Janus droplets, evolving from non-engulfing to complete engulfing core/shell configuration. The produced droplets contain an aqueous phase of dextran (DEX) solution and an oil phase, which is mixed with ethoxylated trimethylolpropane triacrylate (ETPTA) and poly(ethylene glycol) diacrylate (PEGDA). The PEGDA in the oil phase is transferred into the aqueous phase to form complex morphologies due to the phase separation of PEGDA and DEX. The effects are investigated including the ratio of oil to aqueous phase, the content of initial PEGDA, DEX and surfactants, and the type of surfactants. DEX/PEGDA-ETPTA core/shell-single phase Janus droplets are formed with an increasing engulfed oil droplet into the aqueous droplet while the ratio of oil to aqueous phase increases or the initial PEGDA content increases. The high DEX content leads to the DEX-PEGDA-ETPTA doublet Janus. The use of surfactants polyglycerol polyricinoleate (PGPR) and Span 80 results in the formation of DEX/PEGDA/ETPTA single core/double shell and DEX/PEGDA-ETPTA core/shell-single phase Janus droplets, respectively. These complex emulsions are utilized to fabricate solid particles of complex shapes. This method contributes to new material design underpinned by mass transfer and phase separation, which can be extended to other complex emulsion systems.

Photonic Multishells Composed of Cholesteric Liquid Crystals Designed by Controlled Phase Separation in Emulsion Drops

Cholesteric liquid crystals (CLCs), also known as chiral nematic LCs, show a photonic stopband, which is promising for various optical applications. In particular, CLCs confined in microcompartments are useful for sensing, lasing, and optical barcoding at the microscale. The integration of distinct CLCs into single microstructures can provide advanced functionality. In this work, CLC multishells with multiple stopbands are created by liquid-liquid phase separation (LLPS) in a simple yet highly controlled manner. A homogeneous ternary mixture of LC, hydrophilic liquid, and co-solvent is microfluidically emulsified to form uniform oil-in-water drops, which undergo LLPS to form onion-like drops composed of alternating CLC-rich and CLC-depleted layers. The multiplicity is controlled from one to five by adjusting the initial composition of the ternary mixture, which dictates the number of consecutive steps of LLPS. Interestingly, the concentration of the chiral dopant becomes reduced from the outermost to the innermost CLC drop due to uneven partitioning during LLPS, which results in multiple stopbands. Therefore, the photonic multishells show multiple structural colors. In addition, dye-doped multishells provide band-edge lasing at two different wavelengths. This new class of photonic multishells will provide new opportunities for advanced optical applications.

Responsive Janus and Cerberus emulsions via temperature-induced phase separation in aqueous polymer mixtures

Complex aqueous emulsions represent a promising material platform for the encapsulation of cells, pharmaceuticals, or nutrients, for the fabrication of structured particles, as well as for mimicking the barrier-free compartmentalization of biomolecules found in living cells. Herein, we report a novel, simple, and scalable method of creating multicomponent aqueous droplets with highly uniform internal droplet morphologies that can be controllably altered after emulsification by making use of a thermal phase separation approach. Specifically, temperature-induced phase separation inside as-formed emulsion droplets comprising aqueous mixtures of two or more hydrophilic polymers allows for the generation of Janus and Cerberus emulsion droplets with adjustable internal morphologies that are solely controlled by a balance of interfacial tensions. We demonstrate our approach by applying both, microfluidic and scalable batch production, and present a detailed model study with predictive capabilities that enables fine-tuning and dynamically altering the droplet morphology as a function of types, molecular weights, and hydrophilicities of the polymers as well as the surfactant hydrophilic-lipophilic balance. The ability to rationally design complex aqueous emulsion droplets with previously unattainable dynamic control over their morphologies after emulsification entails the potential to design new responsive soft materials with implications for a variety of applications beyond encapsulation, including the design of complex adaptive and self-regulating materials, e.g. for chemical and biological sensing applications.

Simultaneous electric production and sizing of emulsion droplets in microfluidics

Microscale emulsions are widely used in fundamental and applied sciences. To expand their utilization, various methods have been developed for manipulating and measuring the physical properties of fabricated emulsions inside microchannels. Herein, we present an electric emulsification platform that can produce emulsions and simultaneously detect their physical properties (size and production speed). The characterization of the emulsion properties during the fabrication process will broaden the application fields for microscale emulsions because it can avoid time-consuming post image processing and simplify the emulsification platform. To accomplish this, a "bottleneck" channel is implanted between two reservoirs of immiscible fluids (continuous and dispersion phases). This channel can not only confine one fluid within the other when the electric field is on, resulting in emulsification via electrohydrodynamically induced Rayleigh instability, but also act as a resistive pulse sensor (RPS). The fluctuation of the liquid/liquid interface during emulsification induces the fluctuation of the electric resistance in the bottleneck channel, as the two fluid phases have different electrical conductivities. With this simple but dual-functional channel, the emulsion size (radius of 5-10 μm) and production speed (7-12 Hz) can be controlled by adjusting the electric field and the channel-neck geometry. Additionally, the properties can be measured using the RPS; the data obtained through the RPS exhibit high correlations with the validated data obtained using a high-speed camera and microscopy (>95%). The proposed buffer-less electric emulsification with the embedded RPS is a simple and cost-effective emulsion production method that allows real-time emulsion characterization with a limited sample volume.

Observation of osmotically driven, highly controllable and reconfigurable oil/water phase separation

Liquid-liquid phase separation has been proven to be a valuable method for producing structured materials and creating chemical systems. Although several strategies have been developed to date, osmotically driven oil/water phase separation has never been achieved owing to the limited solubility of inorganic salts in conventional organic solvents and thus the insufficient osmotic driving force to counterbalance the Laplace pressure associated with the interfacial tension. Herein, we report the discovery that a mixture of 1-alkyl-3-vinylimidazolium bis(trifluoromethanesulfonyl)imide and LiTf2N can generate sufficient and widely tunable osmotic pressure in oil to realize water transport from the surrounding aqueous phase into the oil phase, triggering spontaneous phase separation. This osmotically driven phase separation could be modulated with unprecedented flexibility, offering unlimited possibilities to facilely access diverse thermodynamically metastable structures using one system. Importantly, this oil system can serve as a general phase separation carrier platform for realizing phase separation of various substances.

A Robust Aqueous Core-Shell-Shell Coconut-like Nanostructure for Stimuli-Responsive Delivery of Hydrophilic Cargo

Conventional delivery systems for hydrophilic material still face critical challenges toward practical applications, including poor retention abilities, lack of stimulus responsiveness, and low bioavailability. Here, we propose a robust encapsulation strategy for hydrophilic cargo to produce a wide class of aqueous core-shell-shell coconut-like nanostructures featuring excellent stability and multifunctionality. The numerous active groups (-SH, -NH₂, and -COOH) of the protein-polysaccharide wall material enable the formation of shell-cross-linked nanocapsules enclosing a liquid water droplet during acoustic cavitation. A subsequent pH switch can trigger the generation of an additional shell through the direct deposition of non-cross-linked protein back onto the cross-linked surface. Using anthocyanin as a model hydrophilic bioactive, these nanocapsules show high encapsulation efficiency, loading content, tolerance to environmental stresses, biocompatibility, and high cellular uptake. Moreover, the composite double shells driven by both covalent bonding and electrostatics provide the nanocapsules with pH/redox dual stimuli-responsive behavior. Our approach is also feasible for any shell material that can be cross-linked via ultrasonication, offering the potential to encapsulate diverse hydrophilic functional components, including bioactive molecules, nanocomplexes, and water-dispersible inorganic nanomaterials. Further development of this strategy should hold promise for designing versatile nanoengineered core-shell-shell nanoplatforms for various applications, such as the oral absorption of hydrophilic drugs/nutraceuticals and the smart delivery of therapeutics.

Thermoresponsive nanoemulsion-based gel synthesized through a low-energy process

Thermoresponsive nanoemulsions find utility in applications ranging from food to pharmaceuticals to consumer products. Prior systems have found limited translation to applications due to cytotoxicity of the compositions and/or difficulties in scaling-up the process. Here, we report a route to thermally gel an oil-in-water nanoemulsion using a small amount of FDA-approved amphiphilic triblock Pluronic copolymers which act as gelling agents. At ambient temperature the suspension displays liquid-like behavior, and quickly becomes an elastic gel at elevated temperatures. We propose a gelation mechanism triggered by synergistic action of thermally-induced adsorption of Pluronic copolymers onto the droplet interface and an increased micelle concentration in the aqueous solution. We demonstrate that the system's properties can be tuned via many factors and report their rheological properties. The nanoemulsions are prepared using a low-energy process which offers an efficient route to scale-up. The nanoemulsion formulations are well-suited for use in cosmetics and pharmaceutical applications.

Microfluidic preparation of polymer-lipid Janus microparticles with staged drug release property

This work demonstrated a microfluidic preparation process for novel Janus microparticles with individual drug release properties in each compartment. A flow-focusing microfluidic chip was designed to produce oil-in-water droplets from a mixed solution of poly(lactic-co-glycolic acid) and a triglyceride type lipid. Based on solvent evaporation-induced phase separation, droplets evolved and were solidified into Janus particles, each of which had a polymer compartment and a lipid compartment. The ratio of the two compartments in a particle can be discretionarily regulated, and the particle structure can also be flexibly altered to Janus-patchy, triple, quadruple or core-shell type. Phase transition of the chosen lipid from solid to liquid would occur under physiological temperature, which was applied for rapid release of the loaded drug. The polymer compartment would undergo a slow degradation process in physiological environment, facilitating sustained drug release. Paclitaxel was loaded into Janus particles during preparation, and staged release was achieved, leading to a combination of rapid and sustained release, which is highly desired in target drug delivery. This study would start the application of hybrid Janus particles of polymer-lipid type with novel release kinetics in drug delivery systems.

Rapid Detection of Salmonella enterica via Directional Emission from Carbohydrate-Functionalized Dynamic Double Emulsions

Reliable early-stage detection of foodborne pathogens is a global public health challenge that requires new and improved sensing strategies. Here, we demonstrate that dynamically reconfigurable fluorescent double emulsions can function as highly responsive optical sensors for the rapid detection of carbohydrates fructose, glucose, mannose, and mannan, which are involved in many biological and pathogenic phenomena. The proposed detection strategy relies on reversible reactions between boronic acid surfactants and carbohydrates at the hydrocarbon/water interface leading to a dynamic reconfiguration of the droplet morphology, which alters the angular distribution of the droplet's fluorescent light emission. We exploit this unique chemical-morphological-optical coupling to detect Salmonella enterica, a type of bacteria with a well-known binding affinity for mannose. We further demonstrate an oriented immobilization of antibodies at the droplet interface to permit higher selectivity. Our demonstrations yield a new, inexpensive, robust, and generalizable sensing strategy that can help to facilitate the early detection of foodborne pathogens.

An ultraviolet-curable, core-shell vaccine formed via phase separation

One of the central challenges in the field of vaccine delivery is to develop a delivery method that maintains antigen stability while also enabling control over the system's release kinetics. Addressing these challenges would not only allow for expanded access to vaccines worldwide but would also help significantly reduce mortality rates in developing countries. In this article, we report the development of single-injection vaccine depots for achieving novel delayed burst release. Synthesized poly(ε-caprolactone) and poly(ε-caprolactone) triacrylate were used to form stationary bubbles within an aqueous solution of 10% carboxymethylcellulose. These polymeric bubbles (referred to as "polybubbles") can then be injected with an aqueous solution of cargo, resulting in the formation of a polymeric shell. The puncture resulting from cargo injection self-heals prior to ultraviolet (UV) curing. UV curing and lyophilization were shown to enhance the stability of the polybubbles. BSA- CF 488 and HIV1 gp120/41 were used as the antigen in the study as a proof-of-concept. Further endeavors to automate the production of polybubbles are underway.

Organic Janus Microspheres: A General Approach to All-Color Dual-Wavelength Microlasers

We propose a general approach for obtaining dual-wavelength organic microlasers in amphiphilic Janus resonators, where hydrophilic and hydrophobic dyes can be spatially separated via polarity-driven encapsulation. Low-threshold dual-wavelength lasing was achieved in a single Janus particle with well-modulated output. This universal approach enables flexibly designing the lasing wavelength of the Janus microlasers in the full visible spectrum by systematically altering the encapsulated laser dyes. Our findings demonstrate a promising route to the photonic integration at the micro-/nanoscale that may lead to the innovation of concepts and device architectures for multifunctional optoelectronic applications.