Why is Micro Segmented Flow Particularly Promising for the Synthesis of Nanomaterials?

Flexible Toolbox of High-Precision Microfluidic Modules for Versatile Droplet-Based Applications

Although the enormous potential of droplet-based microfluidics has been successfully demonstrated in the past two decades for medical, pharmaceutical, and academic applications, its inherent potential has not been fully exploited until now. Nevertheless, the cultivation of biological cells and 3D cell structures like spheroids and organoids, located in serially arranged droplets in micro-channels, has a range of benefits compared to established cultivation techniques based on, e.g., microplates and microchips. To exploit the enormous potential of the droplet-based cell cultivation technique, a number of basic functions have to be fulfilled. In this paper, we describe microfluidic modules to realize the following basic functions with high precision: (i) droplet generation, (ii) mixing of cell suspensions and cell culture media in the droplets, (iii) droplet content detection, and (iv) active fluid injection into serially arranged droplets. The robustness of the functionality of the Two-Fluid Probe is further investigated regarding its droplet generation using different flow rates. Advantages and disadvantages in comparison to chip-based solutions are discussed. New chip-based modules like the gradient, the piezo valve-based conditioning, the analysis, and the microscopy module are characterized in detail and their high-precision functionalities are demonstrated. These microfluidic modules are micro-machined, and as the surfaces of their micro-channels are plasma-treated, we are able to perform cell cultivation experiments using any kind of cell culture media, but without needing to use surfactants. This is even more considerable when droplets are used to investigate cell cultures like stem cells or cancer cells as cell suspensions, as 3D cell structures, or as tissue fragments over days or even weeks for versatile applications.

Sustainable, Green, and Continuous Synthesis of Fivefold Palladium Nanorods Using l-Ascorbic Acid in a Segmented Millifluidic Flow Reactor

Pd nanorods (PdNRs) have recently come to attention due to their wide array of applications. The green synthesis of PdNR with a relatively high yield and high aspect ratio is challenging. A continuous millifluidic flow reactor (CMFR) has been explored to precisely control mass and heat transfer as well as mixing in the PdNR synthesis processes. CMFRs demonstrate a few drawbacks, such as the presence of parabolic velocity profile in the laminar flow of the reaction solution, causing uneven axial residence time distribution. The CMFRs are likely to show irreversible fouling, which may cause the product quality to deteriorate or result in the channel being clogged. These shortcomings can be avoided or minimized using a segmented millifluidic flow reactor (SMFR) that consists of the solution forming a train of individual segments in another inert medium. This study explores the use of a sustainable reducing agent (l-ascorbic acid) in the presence of potassium bromide (KBr) as the capping agent and poly(vinyl pyrrolidone) (PVP) as the stabilizing agent for PdNR synthesis in an SMFR employing compartmentalized flow of a reaction solution, in which liquid segments consisting of a reaction solution will be immersed in the steam generated by boiling of the solvent water. The effect of reaction parameters such as reagent concentration has been studied on the size and morphology of synthesized Pd nanostructures. A kinetic study has been conducted to calculate the rate of reduction that can be used as a quantitative measure for manipulation of the type and relative concentration of initially formed seeds. It has been shown that the initial reduction rate during the first 45 min of residence time of the millifluidic reactor is about 66% faster compared to the rest of the reaction. A filtration procedure has been utilized to separate Pd nanostructures other than nanorods synthesized in the SMFR.

Continuous segmented-flow synthesis of Ag and Au nanoparticles using a low-cost microfluidic PTFE tubing reactor

We present in here a simple and low cost continuous segmented-flow process for the synthesis of Ag and Au spherical-shaped nanoparticles. Different residence times (RT) were used to perform the nanoparticle synthesis, observing that at low RT, the Ag nanoparticles production, which uses a fast reduction reaction with NaBH4, is improved due to an enhancement in the mixing of the reactants. However, the flow conditions have an opposite effect in the case of Au nanoparticles synthesis. Indeed, since the chemical reduction process (Turkevich method) exhibit a much slower kinetics, high RT (low flowrates) improve the synthesis yield and the quality of the nanoparticles. The Ag and Au nanoparticles were characterized by UV-Vis spectrophotometry (UV-Vis) and Transmission Electron Microscopy (TEM). The Ag spherical-shaped nanoparticles presented a LSPR at 400 nm (size ≈ 4 nm), while the synthesized Au nanoparticles exhibit LSPR and sizes in the range 520 - 550 nm and 14 - 17 nm, respectively.

Emerging Structural and Interfacial Features of Particulate Polymers at the Nanoscale

Particulate polymers at the nanoscale are exceedingly promising for diversified functional applications ranging from biomedical and energy to sensing, labeling, and catalysis. Tailored structural features (i.e., size, shape, morphology, internal softness, interior cross-linking, etc.) determine polymer nanoparticles' impact on the cargo loading capacity and controlled/sustained release, possibility of endocytosis, degradability, and photostability. The designed interfacial features, however (i.e., stimuli-responsive surfaces, wrinkling, surface porosity, shell-layer swellability, layer-by-layer surface functionalization, surface charge, etc.), regulate nanoparticles' interfacial interactions, controlled assembly, movement and collision, and compatibility with the surroundings (e.g., solvent and biological environments). These features define nanoparticles' overall properties/functions on the basis of homogeneity, stability, interfacial tension, and minimization of the surface energy barrier. Lowering of the resultant outcomes is directly influenced by inhomogeneity in the structural and interfacial design through the structure-function relationship. Therefore, a key requirement is to produce well-defined polymer nanoparticles with controlled characteristics. Polymers are amorphous, flexible, and soft, and hence controlling their structural/interfacial features through the single-step process is a challenge. The microfluidics reaction strategy is very promising because of its wide range of advantages such as efficient reactant mixing and fast phase transfer. Overall, this feature article highlights the state-of-the-art synthetic features of polymer nanoparticles with perspectives on their advanced applications.

Designs of continuous-flow pharmaceutical crystallizers: developments and practice

This review of recent research advances in continuous-flow crystallization includes a five-step general design procedure, generally applicable process intensification strategies, and practical insights.

Size and shape control of metal nanoparticles in millifluidic reactors

Engineered metal nanoparticles (metal NPs) possess unique size -dependent optical and electronic properties that could enable new applications in biomedicine, energy generation, microelectronics, micro-optics, and catalysis. For metal NPs to make a mark in these fields, however, new synthetic strategies must be developed that permit NP synthesis on the kilogram scale, while maintaining precise control over NP physiochemical properties (size, shape, composition, and surface chemistry). Currently, NP batch syntheses produce product on the milligram scale and rely on synthetic strategies that are not readily amenable to scale-up. Flow reactor systems (including lab-on-a-chip devices) provide a synthesis platform that can circumvent many of the traditional limitations of batch-scale NP syntheses. These reactors provide more uniform reagent mixing, more uniform heat transfer, opportunities to interface in situ monitoring technology, and allow product yield to be scaled up simply by running multiple reactors in parallel. While many NP syntheses have been successfully transferred to microfluidic reactor systems, microfluidic reactor fabrication is time intensive and typically requires sophisticated lithography facilities. Consequently, millifluidic flow reactors (reactors with channel dimensions of 0.5–10.0 mm) are gaining popularity in NP synthesis. These millifluidic reactors provide many of the same synthetic advantages as microfluidic devices, but are simpler to construct, easier to reconfigure, and more straightforward to interface with in situ monitoring techniques. In this chapter, we will discuss the progress that has been made in developing millifluidic reactors for functionalized metal NP synthesis. First, we will review the basic wet-chemical strategies used to control metal NP size and shape in batch reactors. We will then survey some of the basic principles of millifluidic device design, construction, and operation. We will also discuss the potential for incorporating in situ monitoring for quality control during synthesis. We will conclude by highlighting some particularly relevant examples of millifluidic metal NP synthesis that have set new standards for metal NP size, shape, and surface chemistry control.

Graphical Abstract:

Continuous synthesis of gold nanoparticles in micro- and millifluidic systems

Gold nanomaterials have diverse applications ranging from healthcare and nanomedicine to analytical sciences and catalysis. Microfluidic and millifluidic reactors offer multiple advantages for their synthesis and manufacturing, including controlled or fast mixing, accurate reaction time control and excellent heat transfer. These advantages are demonstrated by reviewing gold nanoparticle synthesis strategies in flow devices. However, there are still challenges to be resolved, such as reactor fouling, particularly if robust manufacturing processes are to be developed to achieve the desired targets in terms of nanoparticle size, size distribution, surface properties, process throughput and robustness. Solutions to these challenges are more effective through a coordinated approach from chemists, engineers and physicists, which has at its core a qualitative and quantitative understanding of the synthesis processes and reactor operation. This is important as nanoparticle synthesis is complex, encompassing multiple phenomena interacting with each other, often taking place at short timescales. The proposed methodology for the development of reactors and processes is generic and contains various interconnected considerations. It aims to be a starting point towards rigorous design procedures for the robust and reproducible continuous flow synthesis of gold nanoparticles.

Graphical Abstract:

Wet chemical synthesis of metal oxide nanoparticles: a review

Metal oxide nanoparticles are an important class of nanomaterials that have found several applications in science and technology.

Encoding Microreactors with Droplet Chains in Microfluidics

Droplet-based high throughput biomolecular screening and combinatorial synthesis entail a viable indexing strategy to be developed for the identification of each microreactor. Here, we propose a novel indexing scheme based on the generation of droplet sequences on demand to form unique encoding droplet chains in fluidic networks. These codes are represented by multiunit and multilevel droplets packages, with each code unit possessing several distinct signal levels, potentially allowing large encoding capacity. For proof of concept, we use magnetic nanoparticles as the encoding material and a giant magnetoresistance (GMR) sensor-based active sorting system supplemented with an optical detector to generate and decode the sequence of one exemplar sample droplet reactor and a 4-unit quaternary magnetic code. The indexing capacity offered by 4-unit multilevel codes with this indexing strategy is estimated to exceed 10⁴, which holds great promise for large-scale droplet-based screening and synthesis.

Parametric studies on droplet generation reproducibility for applications with biological relevant fluids

Although the great potential of droplet based microfluidic technologies for routine applications in industry and academia has been successfully demonstrated over the past years, its inherent potential is not fully exploited till now. Especially regarding to the droplet generation reproducibility and stability, two pivotally important parameters for successful applications, there is still a need for improvement. This is even more considerable when droplets are created to investigate tissue fragments or cell cultures (e.g. suspended cells or 3D cell cultures) over days or even weeks. In this study we present microfluidic chips composed of a plasma coated polymer, which allow surfactants-free, highly reproducible and stable droplet generation from fluids like cell culture media. We demonstrate how different microfluidic designs and different flow rates (and flow rate ratios) affect the reproducibility of the droplet generation process and display the applicability for a wide variety of bio(techno)logically relevant media.

Nanoengineering a library of metallic nanostructures using a single microfluidic reactor

Microfluidic synthesis in a microfabricated reactor enables fast and facile synthesis of a wide library of metallic nanostructures: monometallic, bimetallic, anisotropic growth and heterostructures. Specific nanostructures are realized by selection of flow pattern and synthesis parameters. The technique is shown to have advantages over conventional batch technologies. Not only does it allow faster scalable synthesis, but also realization of nanostructures hitherto not reported such as Pt-Ru, Pt-Ni and Pt-Co nanodendrites, Pt-Pd heterostructures, Ag-Pd core-shell NPs, Au-Pd nanodumbbells and Au-Pd nanosheets.

On-demand generation and mixing of liquid-in-gas slugs with digitally-programmable composition and size

Microscopic droplets or slugs of mixed reagents provide a convenient platform for performing large numbers of isolated biochemical or chemical reactions for many screening and optimization applications. Myriad microfluidic approaches have emerged for creating droplets or slugs with controllable size and composition, generally using an immiscible carrier fluid to assist with the formation or merging processes. We report a novel device for generation of liquid slugs in air when the use of a carrier liquid is not compatible with the application. The slug generator contains two adjacent chambers, each of which has a volume that can be digitally adjusted by closing selected microvalves. Reagents are filled into the two chambers, merged together into a contiguous liquid slug, ejected at the desired time from the device using gas pressure, and mixed by flowing in a downstream channel. Programmable size and composition of slugs is achieved by dynamically adjusting the volume of each chamber prior to filling. Slug formation in this fashion is independent of fluid properties and can easily be scaled to mix larger numbers of reagents. This device has already been used to screen monomer ratios in supramolecular nanoparticle assembly and radiolabeling conditions of engineered antibodies, and here we provide a detailed description of the underlying device.

Composite Sensor Particles for Tuned SERS Sensing: Microfluidic Synthesis, Properties and Applications

Surface-enhanced Raman scattering (SERS) is a promising platform for particle-based sensor signaling, and droplet-based microfluidic systems are particularly advantageous for control of the size and composition of micro- and nanoparticles. For controlled sensing application, a high homogeneity of the sensor particles is a key requirement, and the particles with functional properties demand for the preparation in a minimum number of synthesis steps. Frequently used coflow and flow focusing arrangements, however, produce the microparticles of only larger size. To address such concern for downscaling of particle size, which is crucial for strong sensing outcome, we have used a peculiar micro cross-flow arrangement here for generating the polymer microparticles of broad size range between 30 and 600 μm along with in situ embedded silver nanoparticles. Embedded silver acts as nuclei for additional silver enforcement via silver-catalyzed silver deposition in order to realize the composite microparticles for SERS sensing. The homogeneous size and spatial distribution of silver nanoparticles inside the matrix and enforcement over the surface together with controlled pore size provides a high and homogeneous loading of polymer composite sensor. Moreover, different parameters such as analytes concentration and particles size have been studied here for SERS sensing application of biochemical molecules (amino acids and vitamins). Overall, the platform for size-tuned droplets generation, synthesis of composite microparticles, mechanism for synchronized photopolymerization-photoreduction, tuned silver enforcement, and the impacts of different analytes on differently composed microparticles are systematically investigated in this paper.

Control of shape and size of polymer nanoparticles aggregates in a single-step microcontinuous flow process: a case of flower and spherical shapes

Controlled aggregation of polymer nanoparticles for building anisotropic nano- and microstructures via a self-assembling bottom-up process is an important strategy. Therefore, in this work, the formation of structured poly(methyl methacrylate) (PMMA) particles with diameters between lower micrometer and submicrometer range by use of a microcontinuous flow arrangement was investigated in the presence of nonionic water-soluble polymer polyvinylpyrrolidone (PVP). The investigations show that the microreaction strategy is well applicable and allows a tuning of size and shape of nanoparticles in dependence on reactant concentrations and flow rate ratios. Larger and complex structured polymer particles have been found at lower PVP concentration, whereas more compact submicron-sized particles were formed at higher PVP concentrations. The addition of ionic surfactants modulates the generation of characteristic particle shapes. The observation of intermediate states between complex flowerlike particles and simple spheres in dependence on the applied concentration of low molecular weight surfactants supports the explanation of particle formation by a mechanism with superposition of particle growth and assembling. When mixed surfactants (PVP-SDS or PVP-CTAB) are used, the final particles shape depends on the concentration of individual concentrations of surfactants and on the competition between mobility, solvation, and micelle formations.

Nanocrystal synthesis in microfluidic reactors: where next?

The past decade has seen a steady rise in the use of microfluidic reactors for nanocrystal synthesis, with numerous studies reporting improved reaction control relative to conventional batch chemistry. However, flow synthesis procedures continue to lag behind batch methods in terms of chemical sophistication and the range of accessible materials, with most reports having involved simple one- or two-step chemical procedures directly adapted from proven batch protocols. Here we examine the current status of microscale methods for nanocrystal synthesis, and consider what role microreactors might ultimately play in laboratory-scale research and industrial production.

Nanometer precise adjustment of the silver shell thickness during automated Au-Ag core-shell nanoparticle synthesis in micro fluid segment sequences

In this work, a wet-chemical synthesis method for gold-silver core-shell particles with nanometer precise adjustable silver shell thicknesses is presented. Typically wet-chemical syntheses lead to relatively large diameter size distributions and losses in the yield of the desired particle structure due to thermodynamical effects. With the here explained synthesis method in micro fluidic segment sequences, a combinatorial in situ parameter screening of the reactant concentration ratios by programmed flow rate shifts in conjunction with efficient segment internal mixing conditions is possible. The highly increased mixing rates ensure a homogeneous shell deposition on all presented gold core particles while the amount of available silver ions was adjusted by automated flow rate courses, from which the synthesis conditions for exactly tunable shell thicknesses between 1.1 and 6.1 nm could be derived. The findings according to the homogeneity of size and particle structure were confirmed by differential centrifugal sedimentation (DCS), scanning and transmission electron microscopy (SEM, TEM) and X-ray photoelectron spectroscopy (XPS) measurements. In UV-Vis measurements, a significant contribution of the core metal was found in the shape of the extinction spectra in the case of thin shells. These results were confirmed by theoretical calculations.