Fabrication of advanced particles and particle-based materials assisted by droplet-based microfluidics

Dynamic video recognition for cell-encapsulating microfluidic droplets

Droplet microfluidics is a highly sensitive and high-throughput technology extensively utilized in biomedical applications, such as single-cell sequencing and cell screening. However, its performance is highly influenced by the droplet size and single-cell encapsulation rate (following random distribution), thereby creating an urgent need for quality control. Machine learning has the potential to revolutionize droplet microfluidics, but it requires tedious pixel-level annotation for network training. This paper investigates the application software of the weakly supervised cell-counting network (WSCApp) for video recognition of microdroplets. We demonstrated its real-time performance in video processing of microfluidic droplets and further identified the locations of droplets and encapsulated cells. We verified our methods on droplets encapsulating six types of cells/beads, which were collected from various microfluidic structures. Quantitative experimental results showed that our approach can not only accurately distinguish droplet encapsulations (micro-F1 score > 0.94), but also locate each cell without any supervised location information. Furthermore, fine-tuning transfer learning on the pre-trained model also significantly reduced (>80%) annotation. This software provides a user-friendly and assistive annotation platform for the quantitative assessment of cell-encapsulating microfluidic droplets.

Engineering advancements in microfluidic systems for enhanced mixing at low Reynolds numbers

Mixing within micro- and millichannels is a pivotal element across various applications, ranging from chemical synthesis to biomedical diagnostics and environmental monitoring. The inherent low Reynolds number flow in these channels often results in a parabolic velocity profile, leading to a broad residence time distribution. Achieving efficient mixing at such small scales presents unique challenges and opportunities. This review encompasses various techniques and strategies to evaluate and enhance mixing efficiency in these confined environments. It explores the significance of mixing in micro- and millichannels, highlighting its relevance for enhanced reaction kinetics, homogeneity in mixed fluids, and analytical accuracy. We discuss various mixing methodologies that have been employed to get a narrower residence time distribution. The role of channel geometry, flow conditions, and mixing mechanisms in influencing the mixing performance are also discussed. Various emerging technologies and advancements in microfluidic devices and tools specifically designed to enhance mixing efficiency are highlighted. We emphasize the potential applications of micro- and millichannels in fields of nanoparticle synthesis, which can be utilized for biological applications. Additionally, the prospects of machine learning and artificial intelligence are offered toward incorporating better mixing to achieve precise control over nanoparticle synthesis, ultimately enhancing the potential for applications in these miniature fluidic systems.

Revealing the 3D Structure of Block Copolymers with Electron Microscopy: Current Status and Future Directions

Block copolymers (BCPs) are considered model systems for understanding and utilizing self-assembly in soft matter. Their tunable nanometric structure and composition enable comprehensive studies of self-assembly processes as well as make them relevant materials in diverse applications. A key step in developing and controlling BCP nanostructures is a full understanding of their three-dimensional (3D) structure and how this structure is affected by the BCP chemistry, confinement, boundary conditions, and the self-assembly evolution and dynamics. Electron microscopy (EM) is a leading method in BCP 3D characterization owing to its high resolution in imaging nanosized structures. Here we discuss the two main 3D EM methods: namely, transmission EM tomography and slice and view scanning EM tomography. We present each method's principles, examine their strengths and weaknesses, and discuss ways researchers have devised to overcome some of the challenges in BCP 3D characterization with EM- from specimen preparation to imaging radiation-sensitive materials. Importantly, we review current and new cutting-edge EM methods such as direct electron detectors, energy dispersive X-ray spectroscopy of soft matter, high temporal rate imaging, and single-particle analysis that have great potential for expanding the BCP understanding through EM in the future.

Encapsulation of Cadmium-Free InP/ZnSe/ZnS Quantum Dots in Poly(LMA-co-EGDMA) Microparticles via Co-flow Droplet Microfluidics

Quantum dots (QDs) are semiconductor nanocrystals that are used in optoelectronic applications. Most modern QDs are based on toxic metals, for example Cd, and do not comply with the European Restriction of Hazardous Substances regulation of the European Union. Latest promising developments focus on safer QD alternatives based on elements from the III-V group. However, the InP-based QDs lack an overall photostability under environmental influences. One design path of achieving stability is through encapsulation in cross-linked polymer matrices with the possibility to covalently link the matrix to surface ligands of modified core-shell QDs. The work focuses on the formation of polymer microbeads suitable for InP-based QD encapsulation, allowing for an individual protection of QDs and an improved processibility via this particle-based approach. For this, a microfluidic based method in the co-flow regime is used that consists of an oil-in-water droplet system in a glass capillary environment. The generated monomer droplets are polymerized in-flow into poly(LMA-co-EGDMA) microparticles with embedded InP/ZnSe/ZnS QDs using a UV initiation. They demonstrate how a successful polymer microparticle formation via droplet microfluidics produces optimized matrix structures leading to a distinct photostability improvement of InP-based QDs compared to nonprotected QDs.

Core-Shell Particles: From Fabrication Methods to Diverse Manipulation Techniques

Core-shell particles are micro- or nanoparticles with solid, liquid, or gas cores encapsulated by protective solid shells. The unique composition of core and shell materials imparts smart properties on the particles. Core-shell particles are gaining increasing attention as tuneable and versatile carriers for pharmaceutical and biomedical applications including targeted drug delivery, controlled drug release, and biosensing. This review provides an overview of fabrication methods for core-shell particles followed by a brief discussion of their application and a detailed analysis of their manipulation including assembly, sorting, and triggered release. We compile current methodologies employed for manipulation of core-shell particles and demonstrate how existing methods of assembly and sorting micro/nanospheres can be adopted or modified for core-shell particles. Various triggered release approaches for diagnostics and drug delivery are also discussed in detail.

Recent Advances in Microgels: From Biomolecules to Functionality

The emerging applications of hydrogel materials at different length scales, in areas ranging from sustainability to health, have driven the progress in the design and manufacturing of microgels. Microgels can provide miniaturized, monodisperse, and regulatable compartments, which can be spatially separated or interconnected. These microscopic materials provide novel opportunities for generating biomimetic cell culture environments and are thus key to the advances of modern biomedical research. The evolution of the physical and chemical properties has, furthermore, highlighted the potentials of microgels in the context of materials science and bioengineering. This review describes the recent research progress in the fabrication, characterization, and applications of microgels generated from biomolecular building blocks. A key enabling technology allowing the tailoring of the properties of microgels is their synthesis through microfluidic technologies, and this paper highlights recent advances in these areas and their impact on expanding the physicochemical parameter space accessible using microgels. This review finally discusses the emerging roles that microgels play in liquid-liquid phase separation, micromechanics, biosensors, and regenerative medicine.

New long-acting injectable microspheres prepared by IVL-DrugFluidic™ system: 1-month and 3-month in vivo drug delivery of leuprolide

The microspheres for 1-month (PLGA-based) and 3-month (PLA-based) drug releases of leuprolide were manufactured using an IVL-DrugFluidic™ system and their morphology, particle size and distribution, and encapsulation efficiency were compared with the commercialized products. In vivo test was also conducted to monitor the amount of leuprolide and testosterone in plasma after a single subcutaneous injection in male Sprague-Dawley (SD) rats and male Beagle dogs. The median diameter, span value, drug loading, and encapsulation efficiency of PLGA-based microspheres (63.29 μm, 0.26, 13.15%, and 78.90%, respectively) and PLA-based microspheres (80.28 μm, 0.21, 14.42%, and 86.50%, respectively) demonstrated narrow particle size distribution (monodispersed) and efficient drug loading/encapsulation efficiency. Both the microspheres exhibited a desired time-dependent drug release profile and reduced initial burst release by 16-fold in SD rats and 240-fold in Beagle dogs compared to Leuplin DPS®. Moreover, the testosterone level in plasma was suppressed to < 0.50 ng/mL after 28 days with a steady plasma drug concentration. The results suggested that newly developed leuprolide-loaded microspheres produced by the IVL-DrugFluidic™ system could provide extended drug release with advantages such as reduced initial burst release and testosterone level suppression, along with steady plasma drug concentration, over the existing products.

A Facile Single-Phase-Fluid-Driven Bubble Microfluidic Generator for Potential Detection of Viruses Suspended in Air

Microfluidics devices have widely been employed to prepare monodispersed microbubbles/droplets, which have promising applications in biomedical engineering, biosensor detection, drug delivery, etc. However, the current reported microfluidic devices need to control at least two-phase fluids to make microbubbles/droplets. Additionally, it seems to be difficult to make monodispersed microbubbles from the ambient air using currently reported microfluidic structures. Here, we present a facile approach to making monodispersed microbubbles directly from the ambient air by driving single-phase fluid. The reported single-phase-fluid microfluidic (SPFM) device has a typical co-flow structure, while the adjacent space between the injection tube and the collection tube is open to the air. The flow condition inside the SPFM device was systematically studied. By adjusting the flow rate of the single-phase fluid, bubbles were generated, the sizes of which could be tuned precisely. This facile bubble generator may have significant potential as a detection sensor in detecting viruses in spread droplets or haze particles in ambient air.

Biodegradable Microparticles for Regenerative Medicine: A State of the Art and Trends to Clinical Application

Tissue engineering and cell therapy are very attractive in terms of potential applications but remain quite challenging regarding the clinical aspects. Amongst the different strategies proposed to facilitate their implementation in clinical practices, biodegradable microparticles have shown promising outcomes with several advantages and potentialities. This critical review aims to establish a survey of the most relevant materials and processing techniques to prepare these micro vehicles. Special attention will be paid to their main potential applications, considering the regulatory constraints and the relative easiness to implement their production at an industrial level to better evaluate their application in clinical practices.

Spray-Assisted Formation of Micrometer-Sized Emulsions

Emulsion drops with defined sizes are frequently used to conduct chemical reactions on picoliter scales or as templates to form microparticles. Despite tremendous progress that has been achieved in the production of emulsions, the high throughput formation of drops with well-defined diameters of a few micrometers remains challenging. Drops of this size, however, are in high demand, for example, for many pharmaceutical, food, and materials science applications. Here, we introduce a scalable method to produce water-in-oil emulsion drops possessing controlled diameters of just a few micrometers: We fabricate calibrated aerosol drops and transfer them into an oil bath to form stable emulsions at rates up to 480 μL min^-1 of the dispersed phase. We demonstrate that the emulsification is thermodynamically driven such that design principles to successfully form emulsions can easily be deduced. We employ these emulsion drops as templates to form well-defined micrometer-sized hydrogel spheres and capsules.

Preparation of ethyl cellulose particles with different morphologies through microfluidics

The sizes and shapes of polymer particles determine their performance and application. In this paper, ethyl cellulose particles with different morphologies are generated through extraction and solidification in a microfluidic device with double T-junctions. Droplets of ethyl acetate containing ethyl cellulose are formed first, then, pure water is employed to extract the solvents in the droplets and the ethyl cellulose is solidified to form monodisperse particles. By changing the flow rates of the continuous phase and the dispersed phase and the concentration of ethyl cellulose, red-blood-cell-like, doughnut-like, dimpled and spherical particles are fabricated, and the regime of different particle morphologies is given. The more important is that the physical mechanisms and explanations of the formation of different particle morphologies are clearly disclosed by analyzing the circulation flows outside and inside the droplets. The flow patterns in the microchannel, and the diffusion and solidification properties of the molecules are the key factors that affect the final morphology of particles. Due to the circulation, there are two stagnation points at the front and rear of the droplet, and they are the approximate locations where the dimple in the dimpled particle, the hole in the doughnut-like particle and the two pits in the red-blood-cell-like particles are formed. These analysis and results are useful in flow chemistry, in the fabrication of particle materials, and so on.

Advanced Microfluidic Technologies for Lipid Nano-Microsystems from Synthesis to Biological Application

Microfluidics is an emerging technology that can be employed as a powerful tool for designing lipid nano-microsized structures for biological applications. Those lipid structures can be used as carrying vehicles for a wide range of drugs and genetic materials. Microfluidic technology also allows the design of sustainable processes with less financial demand, while it can be scaled up using parallelization to increase production. From this perspective, this article reviews the recent advances in the synthesis of lipid-based nanostructures through microfluidics (liposomes, lipoplexes, lipid nanoparticles, core-shell nanoparticles, and biomimetic nanovesicles). Besides that, this review describes the recent microfluidic approaches to produce lipid micro-sized structures as giant unilamellar vesicles. New strategies are also described for the controlled release of the lipid payloads using microgels and droplet-based microfluidics. To address the importance of microfluidics for lipid-nanoparticle screening, an overview of how microfluidic systems can be used to mimic the cellular environment is also presented. Future trends and perspectives in designing novel nano and micro scales are also discussed herein.

Fabrication of sharp-edged 3D microparticles via folded PDMS microfluidic channels

3D microparticles have promising applications in self-assembly, biomedical engineering, mechanical engineering, etc. The shape of microparticles plays a significant role in their functionalities. Although numerous investigations have been conducted to tailor the shape of microparticles, the diversity is still limited, and it remains a challenge to fabricate 3D microparticles with sharp edges. Here, we present a facile approach that combines a folded PDMS channel and orthogonal projection lithography for shaping sharp-edged 3D microparticles. By adjusting the number and the length of channel sides, both regular and irregular polyhedral cross-sections of the folded channel can be obtained. UV light with diverse patterns is applied vertically as the second shape controlling factor. A variety of 3D microparticles are obtained with sharp edges, which are potential templates for micromachining tools and abrasives. Some sharp-edged microparticles are assembled into 2D and 3D mesoscale structures, which demonstrates their prospective applications in self-assembly, tissue engineering, etc.

Three months extended-release microspheres prepared by multi-microchannel microfluidics in beagle dog models

To evaluate in vivo drug release profiles in beagle dogs, finasteride-loaded PLGA microspheres were prepared using a novel method of IVL-PPF Microsphere® microfluidic device. Briefly, the dispersed phase (PLGA and finasteride in dichloromethane) was mixed with the continuous phase (0.25% w/v PVA aqueous solution) in the parallelized microchannels. After lyophilization, the diameter of the microspheres was around 40 μm (PLGA 7502A or 5002A) and around 30 µm (PLGA/PLA02A mixture). Their CV and span values suggested a narrow size distribution in repeated batch preparations. The in vivo drug release from the PLGA microspheres exhibited three substantial phases: an initial burst, a moderate release, and then a plateau. The microspheres based on PLGA 7502A (75:25 co-polymer) demonstrated extended drug release for around 1 month with a minimized initial burst release compared to PLGA 5002A (50:50 co-polymer). Moreover, the in vivo drug release profile in beagle dogs was proportionally related to the amount of drug loading. Furthermore, the addition of PLA02A into the fabrication of the microsphere synergistically extended the drug release up to 3 months. These results demonstrated the value of this method to achieve uniform microspheres and extend the drug release properties with interpretative in vivo PK profiles.

Microfluidic Chip Device for In Situ Mixing and Fabrication of Hydrogel Microspheres via Michael-Type Addition

Hydrogel microspheres are sought for a variety of biomedical applications, including therapeutic and cellular delivery, sensors, and lubricants. Robust fabrication of hydrogel microspheres with uniform sizes and properties can be achieved using microfluidic systems that rely on droplet formation and subsequent gelation to form microspheres. Such systems work well when gelation is initiated after droplet formation but are not practical for timed gelation systems where gelation is initiated prior to droplet formation; premature gelation can lead to device blockage, variable microsphere diameter due to viscosity changes in the precursor solution, and limited numbers of microspheres produced in a single run. To enable microfluidic fabrication of microspheres from timed gelation hydrogel systems, an in situ mixing region is needed so that various hydrogel precursor components can be added separately. Here, we designed and evaluated three mixing devices for their effectiveness at mixing hydrogel precursor solutions prior to droplet formation and subsequent gelation. The serpentine geometry was found to be the most effective and was further improved with the inclusion of a pillar array to increase agitation. The optimized device was shown to fully mix precursor solutions and enable the fabrication of monodisperse polyethylene glycol microspheres, offering great potential for use with timed gelation hydrogel systems.

Fabrication of Microparticles with Front-Back Asymmetric Shapes Using Anisotropic Gelation

Droplet-based microfluidics is a powerful tool for producing monodispersed micrometer-sized droplets with controlled sizes and shapes; thus, it has been widely applied in diverse fields from fundamental science to industries. Toward a simpler method for fabricating microparticles with front–back asymmetry in their shapes, we studied anisotropic gelation of alginate droplets, which occurs inside a flow-focusing microfluidic device. In the proposed method, sodium alginate (NaAlg) aqueous phase fused with a calcium chloride (CaCl2) emulsion dispersed in the organic phase just before the aqueous phase breaks up into the droplets. The fused droplet with a front–back asymmetric shape was generated, and the asymmetric shape was kept after geometrical confinement by a narrow microchannel was removed. The shape of the fused droplet depended on the size of prefused NaAlg aqueous phase and a CaCl2 emulsion, and the front–back asymmetry appeared in the case of the smaller emulsion size. The analysis of the velocity field inside and around the droplet revealed that the stagnation point at the tip of the aqueous phase also played an important role. The proposed mechanism will be potentially applicable as a novel fabrication technique of microparticles with asymmetric shapes.

Recent Innovations in Emulsion Science and Technology for Food Applications

Emulsion technology has been used for decades in the food industry to create a diverse range of products, including homogenized milk, creams, dips, dressings, sauces, desserts, and toppings. Recently, however, there have been important advances in emulsion science that are leading to new approaches to improving food quality and functionality. This article provides an overview of a number of these advanced emulsion technologies, including Pickering emulsions, high internal phase emulsions (HIPEs), nanoemulsions, and multiple emulsions. Pickering emulsions are stabilized by particle-based emulsifiers, which may be synthetic or natural, rather than conventional molecular emulsifiers. HIPEs are emulsions where the concentration of the disperse phase exceeds the close packing limit (usually >74%), which leads to novel textural properties and high resistance to gravitational separation. Nanoemulsions contain very small droplets (typically d < 200 nm), which leads to useful functional attributes, such as high optical clarity, resistance to gravitational separation and aggregation, rapid digestion, and high bioavailability. Multiple emulsions contain droplets that have smaller immiscible droplets inside them, which can be used for reduced-calorie, encapsulation, and delivery purposes. This new generation of advanced emulsions may lead to food and beverage products with improved quality, health, and sustainability.

Chips for Biomaterials and Biomaterials for Chips: Recent Advances at the Interface between Microfabrication and Biomaterials Research

In recent years, the use of microfabrication techniques has allowed biomaterials studies which were originally carried out at larger length scales to be miniaturized as so-called "on-chip" experiments. These miniaturized experiments have a range of advantages which have led to an increase in their popularity. A range of biomaterial shapes and compositions are synthesized or manufactured on chip. Moreover, chips are developed to investigate specific aspects of interactions between biomaterials and biological systems. Finally, biomaterials are used in microfabricated devices to replicate the physiological microenvironment in studies using so-called "organ-on-chip," "tissue-on-chip" or "disease-on-chip" models, which can reduce the use of animal models with their inherent high cost and ethical issues, and due to the possible use of human cells can increase the translation of research from lab to clinic. This review gives an overview of recent developments at the interface between microfabrication and biomaterials science, and indicates potential future directions that the field may take. In particular, a trend toward increased scale and automation is apparent, allowing both industrial production of micron-scale biomaterials and high-throughput screening of the interaction of diverse materials libraries with cells and bioengineered tissues and organs.

Microfluidic on-chip production of microgels using combined geometries

Microfluidic on-chip production of microgels using external gelation can serve numerous applications that involve encapsulation of sensitive cargos. Nevertheless, on-chip production of microgels in microfluidic devices can be challenging due to problems induced by the rapid increase in precursor solution viscosity like clogging. Here, a novel design incorporating a step, which includes a sudden increase in cross-sectional area, before a flow-focusing nozzle was proposed for microfluidic droplet generators. Besides, a shielding oil phase was utilized to avoid the occurrence of emulsification and gelation stages simultaneously. The step which was located before the flow-focusing nozzle facilitated the full shielding of the dispersed phase due to 3-dimensional fluid flow in this geometry. The results showed that the microfluidic device was capable of generating highly monodispersed spherical droplets (CV < 2% for step and CV < 5% for flow-focusing nozzle) with an average diameter in the range of 90-190 μm, both in step and flow-focusing nozzle. Moreover, it was proved that the device could adequately create a shelter for the dispersed phase regardless of the droplet formation locus. The ability of this microfluidic device in the production of microgels was validated by creating alginate microgels (with an average diameter of ~ 100 μm) through an external gelation process with on-chip calcium chloride emulsion in mineral oil.

Three-dimensional visualization and analysis of flowing droplets in microchannels using real-time quantitative phase microscopy

Recent years have witnessed the development of droplet-based microfluidics as a useful and effective tool for high-throughput analysis in biological, chemical and environmental sciences. Despite the flourishing development of droplet manipulation techniques, only a few methods allow for label-free and quantitative inspection of flowing droplets in microchannels in real-time and in three dimensions (3-D). In this work, we propose and demonstrate the application of a real-time quantitative phase microscopy (RT-QPM) technique for 3-D visualization of droplets, and also for full-field and label-free measurement of analyte concentration distribution in the droplets. The phase imaging system consists of a linear-CCD-based holographic microscopy configuration and an optofluidic phase-shifting element, which can be used for retrieving quantitative phase maps of flowing objects in the microchannels with a temporal resolution only limited to the frame rate of the CCD camera. To demonstrate the capabilities of the proposed imaging technique, we have experimentally validated the 3-D image reconstruction of the droplets generated in squeezing and dripping regimes and quantitatively investigated the volumetric and morphological variation of droplets as well as droplet parameters related to the depth direction under different flow conditions. We also demonstrated the feasibility of using this technique, as a refractive index sensor, for in-line quantitative measurement of carbamide analyte concentration within the flowing droplets.

Dripping, jetting and tip streaming

Dripping, jetting and tip streaming have been studied up to a certain point separately by both fluid mechanics and microfluidics communities, the former focusing on fundamental aspects while the latter on applications. Here, we intend to review this field from a global perspective by considering and linking the two sides of the problem. First, we present the theoretical model used to study interfacial flows arising in droplet-based microfluidics, paying attention to three elements commonly present in applications: viscoelasticity, electric fields and surfactants. We review both classical and current results of the stability of jets affected by these elements. Mechanisms leading to the breakup of jets to produce drops are reviewed as well, including some recent advances in this field. We also consider the relatively scarce theoretical studies on the emergence and stability of tip streaming in open systems. Second, we focus on axisymmetric microfluidic configurations which can operate on the dripping and jetting modes either in a direct (standard) way or via tip streaming. We present the dimensionless parameters characterizing these configurations, the scaling laws which allow predicting the size of the resulting droplets and bubbles, as well as those delimiting the parameter windows where tip streaming can be found. Special attention is paid to electrospray and flow focusing, two of the techniques more frequently used in continuous drop production microfluidics. We aim to connect experimental observations described in this section of topics with fundamental and general aspects described in the first part of the review. This work closes with some prospects at both fundamental and practical levels.

Microfluidic synthesis of monodisperse porous polystyrene microspheres for sorption of bovine serum albumin

Droplet microfluidics offers exquisite control over the flows of multiple fluids in micro-scale, enabling fabrication of advanced microspheres with precisely tuneable structures. The main goal of this work was to design monodispersed carboxylated polystyrene microspheres with a developed pore structure (a specific surface area more than 200 m²/g) using microfluidic technology. We investigated the influence of the composition of monomer phase for the stable formation of droplets. Under the stable region, the resulting microspheres (with diameter 50 µm) showed narrow size distribution having a coefficient of variation of below 2%. The obtained microspheres are characterised by morphology and surface structure by means of electron microscopy. The structure of cross-linked microspheres is investigated by solid-state ¹H NMR spectroscopy. Finally, these microspheres have great potential for the effective sorption of biologically active substances (bovine serum albumin).

Microfluidics for ZnO micro-/nanomaterials development: rational design, controllable synthesis, and on-chip bioapplications

Zinc oxide (ZnO) materials hold great promise in diverse applications due to their attractive physicochemical features. Recent years, especially the last decade, have witnessed considerable progress toward rational design and bioapplications of multiscale ZnO materials through microfluidic techniques. Design of a microfluidic device that allows for precise control over reaction conditions could not only yield ZnO particles with a fast production rate and high quality, but also permit downstream applications with desirable and superior performance. This review summarizes microfluidic approaches for the synthesis and applications of ZnO micro-/nanomaterials. In particular, we discuss the recent achievement of using microfluidic reactors in the controllable synthesis of ZnO structures (wire, rod, sphere, flower, sheet, flake, spindle, and ellipsoid), and highlight the unprecedented opportunities for applying them in biosensing, biological separation, and molecular catalysis applications through microfluidic chips. Finally, major challenges and potential opportunities are explored to guide future studies in this area.

Creation of Nonspherical Microparticles through Osmosis-Driven Arrested Coalescence of Microfluidic Emulsions

Droplet-based microfluidics enable the production of emulsions and microparticles with spherical shapes, but the high-throughput fabrication of nonspherical emulsions and microparticles still remains challenging because interfacial tension plays a dominant role during preparation. Herein, ionic liquids (ILs) containing salts, which possess sufficient osmotic pressure to realize water transport and phase separation, are introduced as inner cores of oil-in-oil-in-water double emulsions and it is shown that nonspherical emulsions can be constructed by osmosis-driven arrested coalescence of inner cores. Subsequently, ultraviolet polymerization of the nonspherical emulsions leads to nonspherical microparticles. By tailoring the number, composition, and size of inner cores as well as coalescence time, a variety of nonspherical shapes such as dumbbell, rod, spindle, snowman, tumbler, three-pointed star, triangle, and scalene triangle are created. Importantly, benefitting from excellent solvency of ILs, this system can serve as a general platform to produce nonspherical microparticles made from different materials. Moreover, by controlling the osmotic pressure, programmed coalescence of inner cores in double emulsions is realizable, which indicates the potential to build microreactors. Thus, a simple and high-throughput strategy to create nonspherical microparticles with arrested coalescence shapes is developed for the first time and can be further used to construct novel materials and microreactors.

Microfluidic Platforms toward Rational Material Fabrication for Biomedical Applications

The emergence of micro/nanomaterials in recent decades has brought promising alternative approaches in various biomedicine-related fields such as pharmaceutics, diagnostics, and therapeutics. These micro/nanomaterials for specific biomedical applications shall possess tailored properties and functionalities that are closely correlated to their geometries, structures, and compositions, therefore placing extremely high demands for manufacturing techniques. Owing to the superior capabilities in manipulating fluids and droplets at microscale, microfluidics has offered robust and versatile platform technologies enabling rational design and fabrication of micro/nanomaterials with precisely controlled geometries, structures and compositions in high throughput manners, making them excellent candidates for a variety of biomedical applications. This review briefly summarizes the progress of microfluidics in the fabrication of various micro/nanomaterials ranging from 0D (particles), 1D (fibers) to 2D/3D (film and bulk materials) materials with controllable geometries, structures, and compositions. The applications of these microfluidic-based materials in the fields of diagnostics, drug delivery, organs-on-chips, tissue engineering, and stimuli-responsive biodevices are introduced. Finally, an outlook is discussed on the future direction of microfluidic platforms for generating materials with superior properties and on-demand functionalities. The integration of new materials and techniques with microfluidics will pave new avenues for preparing advanced micro/nanomaterials with enhanced performance for biomedical applications.

Fabrication and application of complex microcapsules: a review

The development of new functional materials requires cutting-edge technologies for incorporating different functional materials without reducing their functionality. Microencapsulation is a method to encapsulate different functional materials at nano- and micro-scales, which can provide the necessary protection for the encapsulated materials. In this review, microencapsulation is categorized into chemical, physical, physico-chemical and microfluidic methods. The focus of this review is to describe these four categories in detail by elaborating their various microencapsulation methods and mechanisms. This review further discusses the key features and potential applications of each method. Through this review, the readers could be aware of many aspects of this field from the fabrication processes, to the main properties, and to the applications of microcapsules.

Formation of Polarized, Functional Artificial Cells from Compartmentalized Droplet Networks and Nanomaterials, Using One-Step, Dual-Material 3D-Printed Microfluidics

The bottom-up construction of synthetic cells with user-defined chemical organization holds considerable promise in the creation of bioinspired materials. Complex emulsions, droplet networks, and nested vesicles all represent platforms for the engineering of segregated chemistries with controlled communication, analogous to biological cells. Microfluidic manufacture of such droplet-based materials typically results in radial or axisymmetric structures. In contrast, biological cells frequently display chemical polarity or gradients, which enable the determination of directionality, and inform higher-order interactions. Here, a dual-material, 3D-printing methodology to produce microfluidic architectures that enable the construction of functional, asymmetric, hierarchical, emulsion-based artificial cellular chassis is developed. These materials incorporate droplet networks, lipid membranes, and nanoparticle components. Microfluidic 3D-channel arrangements enable symmetry-breaking and the spatial patterning of droplet hierarchies. This approach can produce internal gradients and hemispherically patterned, multilayered shells alongside chemical compartmentalization. Such organization enables incorporation of organic and inorganic components, including lipid bilayers, within the same entity. In this way, functional polarization, that imparts individual and collective directionality on the resulting artificial cells, is demonstrated. This approach enables exploitation of polarity and asymmetry, in conjunction with compartmentalized and networked chemistry, in single and higher-order organized structures, thereby increasing the palette of functionality in artificial cellular materials.

Production of monodisperse polyurea microcapsules using microfluidics

Methods to make microcapsules - used in a broad range of healthcare and energy applications - currently suffer from poor size control, limiting the establishment of size/property relationships. Here, we use microfluidics to produce monodisperse polyurea microcapsules (PUMC) with a limonene core. Using varied flow rates and a commercial glass chip, we produce capsules with mean diameters of 27, 30, 32, 34, and 35 µm, achieving narrow capsule size distributions of ±2 µm for each size. We describe an automated method of sizing droplets as they are produced using video recording and custom Python code. The sustainable generation of such size-controlled PUMCs, potential replacements for commercial encapsulated systems, will allow new insights into the effect of particle size on performance.

Protein Microgels from Amyloid Fibril Networks

Nanofibrillar forms of amyloidogenic proteins were initially discovered in the context of protein misfolding and disease but have more recently been found at the origin of key biological functionality in many naturally occurring functional materials, such as adhesives and biofilm coatings. Their physiological roles in nature reflect their great strength and stability, which has led to the exploration of their use as the basis of artificial protein-based functional materials. Particularly for biomedical applications, they represent attractive building blocks for the development of, for instance, drug carrier agents due to their inherent biocompatibility and biodegradability. Furthermore, the propensity of proteins to self-assemble into amyloid fibrils can be exploited under microconfinement, afforded by droplet microfluidic techniques. This approach allows the generation of multi-scale functional microgels that can host biological additives and can be designed to incorporate additional functionality, such as to aid targeted drug delivery.

Grooved step emulsification systems optimize the throughput of passive generation of monodisperse emulsions

Microfluidic step emulsification passively produces highly monodisperse droplets and can be easily parallelized for high throughput emulsion production. The two main techniques used for step emulsification are: i) edge-based droplet generation (EDGE), where droplets are formed in a single, very wide and shallow nozzle, and ii) microchannel emulsification (MCE), where droplets are formed in many separated narrow nozzles. These techniques differ in modes of droplet formation that influence the throughput and monodispersity of produced emulsions. Here we report a systematic study of novel grooved step emulsifying geometries, a hybrid of MCE and EDGE architectures. We introduce partitions of different heights to a wide (EDGE-like) slit to establish optimal geometries for high-throughput droplet production. We demonstrate that the volume and monodispersity of the produced emulsion can be tuned solely by changing the height of these partitions. We show that the spacing of the partitions influences the size of the produced droplets, but not the population monodispersity. We also determine the moment of transition between two distinct droplet generation modes as a function of the geometrical parameters of the nozzle. The optimized grooved geometry appears to combine the advantages of both MCE and EDGE, i.e. spatial localization of droplet forming units (DFUs), high-throughput formation of tightly monodisperse droplets from parallel DFUs, and low sensitivity to variation in the flow rate of the dispersed phase. As a proof-of-concept we show grooved devices that for a 260-fold increase of flow rate produce droplets with volume increased by just 75%, as compared to 91% increase in volume over a 180-fold increase of flow rate of the dispersed phase in MCE devices. We also present the optimum microfluidic device geometry that almost doubles the throughput of an MCE device in the generation of nanoliter droplets.

Nano-in-Micro Smart Hydrogel Composite for a Rapid Sensitive Immunoassay

Immunoassays are an important tool in various bioanalytical settings, such as clinical diagnostics, biopharmaceutical analysis, environmental monitoring, and food testing. An enzyme-linked immunosorbent assay (ELISA) is usually used to amplify immunoassay signals; however, it requires labor-intensive and time-consuming procedures, which hinders its application to rapid cytokine detection. In this study, a nano-in-micro composite system, where immunosensing polystyrene beads (≈320 nm) are incorporated within a stimuli-responsive microgel matrix (≈40 µm) via microfluidics, is investigated. The intrinsic volume phase-transition change properties of the smart microgels allows an enzyme-free enhanced immunoassay, enabling instant enhancement in signal-to-noise ratios of ≈5-fold. This nano-in-micro hydrogel composite offers a simple yet highly effective method for sensitive and multiplexed cytokine analysis without complex enzyme-based signal amplification steps, greatly benefitting advanced immune medicine.

Microfluidics for the Production of Nanomedicines: Considerations for Polymer and Lipid-based Systems

BACKGROUND

Microfluidics is becoming increasingly of interest as a superior technique for the synthesis of nanoparticles, particularly for their use in nanomedicine. In microfluidics, small volumes of liquid reagents are rapidly mixed in a microchannel in a highly controlled manner to form nanoparticles with tunable and reproducible structure that can be tailored for drug delivery. Both polymer and lipid-based nanoparticles are utilized in nanomedicine and both are amenable to preparation by microfluidic approaches.

AIM

Therefore, the purpose of this review is to collect the current state of knowledge on the microfluidic preparation of polymeric and lipid nanoparticles for pharmaceutical applications, including descriptions of the main synthesis modalities. Of special interest are the mechanisms involved in nanoparticle formation and the options for surface functionalisation to enhance cellular interactions.

CONCLUSION

The review will conclude with the identification of key considerations for the production of polymeric and lipid nanoparticles using microfluidic approaches.