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Mun SJ, Jang W, Choi JH, Lim YJ, Bong KW. Air-through-precursor suction-augmented replica molding for fabrication of anisotropic microparticles in gas-impermeable molds. RSC Adv 2024; 14:25190-25197. [PMID: 39139226 PMCID: PMC11317880 DOI: 10.1039/d4ra04719b] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/29/2024] [Accepted: 08/05/2024] [Indexed: 08/15/2024] Open
Abstract
Replica molding (REM) is a powerful technique for fabricating anisotropic microparticles. Current REM methods rely on the use of gas-permeable molds for defect-free castings and facile particle recovery. However, they often encounter limitations on either technical accessibility or producible particle diversity. While the use of gas-impermeable molds presents a promising solution to these challenges, particle production within such molds necessitates addressing two critical issues: precursor loading and particle recovery. This study introduces a REM methodology specifically tailored to enable the production of anisotropic microparticles within gas-impermeable molds. To address the issue of precursor loading, our approach incorporates the air-through-precursor suction method, employing a degassed polydimethylsiloxane block to effectively eliminate air bubbles trapped in microwells. Additionally, fluorosilane pretreatment of the mold surface, along with the polyvinyl alcohol film formation, significantly enhances particle recovery up to 249-fold while ensuring particle homogeneity. This methodology demonstrates high adaptability to various gas-impermeable molds and curing techniques. The practical feasibility is illustrated through the successful production of functional composite microparticles that can be effectively utilized for oxygen sensing and self-assembly, challenging in conventional REM.
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Affiliation(s)
- Seok Joon Mun
- Department of Chemical and Biological Engineering, Korea University Seoul 02841 Republic of Korea
| | - Wookyoung Jang
- Department of Chemical and Biological Engineering, Korea University Seoul 02841 Republic of Korea
| | - Jun Hee Choi
- Department of Chemical and Biological Engineering, Korea University Seoul 02841 Republic of Korea
| | - Yong Jun Lim
- Department of Chemical and Biological Engineering, Korea University Seoul 02841 Republic of Korea
| | - Ki Wan Bong
- Department of Chemical and Biological Engineering, Korea University Seoul 02841 Republic of Korea
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Ma L, Zhao X, Hou J, Huang L, Yao Y, Ding Z, Wei J, Hao N. Droplet Microfluidic Devices: Working Principles, Fabrication Methods, and Scale-Up Applications. SMALL METHODS 2024; 8:e2301406. [PMID: 38594964 DOI: 10.1002/smtd.202301406] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/13/2023] [Revised: 11/01/2023] [Indexed: 04/11/2024]
Abstract
Compared with the conventional emulsification method, droplets generated within microfluidic devices exhibit distinct advantages such as precise control of fluids, exceptional monodispersity, uniform morphology, flexible manipulation, and narrow size distribution. These inherent benefits, including intrinsic safety, excellent heat and mass transfer capabilities, and large surface-to-volume ratio, have led to the widespread applications of droplet-based microfluidics across diverse fields, encompassing chemical engineering, particle synthesis, biological detection, diagnostics, emulsion preparation, and pharmaceuticals. However, despite its promising potential for versatile applications, the practical utilization of this technology in commercial and industrial is extremely limited to the inherently low production rates achievable within a single microchannel. Over the past two decades, droplet-based microfluidics has evolved significantly, considerably transitioning from a proof-of-concept stage to industrialization. And now there is a growing trend towards translating academic research into commercial and industrial applications, primarily driven by the burgeoning demands of various fields. This paper comprehensively reviews recent advancements in droplet-based microfluidics, covering the fundamental working principles and the critical aspect of scale-up integration from working principles to scale-up integration. Based on the existing scale-up strategies, the paper also outlines the future research directions, identifies the potential opportunities, and addresses the typical unsolved challenges.
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Affiliation(s)
- Li Ma
- School of Chemical Engineering and Technology, Xi'an Jiaotong University, 28 Xianning West Road, Xi'an, Shaanxi, 710049, P. R. China
| | - Xiong Zhao
- School of Chemical Engineering and Technology, Xi'an Jiaotong University, 28 Xianning West Road, Xi'an, Shaanxi, 710049, P. R. China
| | - Junsheng Hou
- School of Chemical Engineering and Technology, Xi'an Jiaotong University, 28 Xianning West Road, Xi'an, Shaanxi, 710049, P. R. China
| | - Lei Huang
- School of Chemical Engineering and Technology, Xi'an Jiaotong University, 28 Xianning West Road, Xi'an, Shaanxi, 710049, P. R. China
| | - Yilong Yao
- School of Chemical Engineering and Technology, Xi'an Jiaotong University, 28 Xianning West Road, Xi'an, Shaanxi, 710049, P. R. China
| | - Zihan Ding
- School of Chemical Engineering and Technology, Xi'an Jiaotong University, 28 Xianning West Road, Xi'an, Shaanxi, 710049, P. R. China
| | - Jinjia Wei
- School of Chemical Engineering and Technology, Xi'an Jiaotong University, 28 Xianning West Road, Xi'an, Shaanxi, 710049, P. R. China
| | - Nanjing Hao
- School of Chemical Engineering and Technology, Xi'an Jiaotong University, 28 Xianning West Road, Xi'an, Shaanxi, 710049, P. R. China
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Zhu Y, Fan R, Zheng Z, Zhu Z, Si T, Xu RX. Preparation of Anisotropic Micro-Hydrogels with Tunable Structural and Topographic Features by Compound Interfacial Shearing. ACS APPLIED MATERIALS & INTERFACES 2021; 13:42114-42124. [PMID: 34428375 DOI: 10.1021/acsami.1c08744] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/13/2023]
Abstract
We propose a compound interfacial shearing (CIS) process for versatile production of monodisperse Janus emulsions with controllable structural and topographic features. The process induces an active periodic force to decouple material and process parameters, enables independent control of compartmental features in Janus emulsions, and facilitates inline and on-demand generation of various geometric features for a large variety of process parameters and material properties. Janus emulsions of poly(ethylene glycol) diacrylate (PEGDA) with a controlled number of compartments are produced by CIS and photopolymerized to form micro-hydrogels with designated interfacial curvatures. PEGDA micro-hydrogels can be further modified to achieve anisotropy of surface or internal features by the content of an oily dispersed phase. MCF-7 human breast cancer cells are encapsulated in micro-hydrogels for cell proliferation with satisfactory viability. By modifying PEGDA micro-hydrogels with RGDS-conjugated polystyrene microspheres, we have demonstrated the controlled spatial adhesion of MCF-7 cells and human umbilical vein endothelial cells (HUVECs) on the substrates of different three-dimensional (3D) curvatures. Our pilot study suggests a simple and potentially scalable approach to produce 3D substrates with controllable structural and topographic features for 3D guided cell organization.
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Affiliation(s)
- Yuanqing Zhu
- Department of Precision Machinery and Precision Instrumentation, University of Science and Technology of China, Hefei, Anhui 230026, China
- Key Laboratory of Precision Scientific Instrumentation of Anhui Higher Education Institutes, University of Science and Technology of China, Hefei 230026, China
| | - Rong Fan
- Department of Precision Machinery and Precision Instrumentation, University of Science and Technology of China, Hefei, Anhui 230026, China
- Key Laboratory of Precision Scientific Instrumentation of Anhui Higher Education Institutes, University of Science and Technology of China, Hefei 230026, China
| | - Zhiyuan Zheng
- Department of Precision Machinery and Precision Instrumentation, University of Science and Technology of China, Hefei, Anhui 230026, China
- Key Laboratory of Precision Scientific Instrumentation of Anhui Higher Education Institutes, University of Science and Technology of China, Hefei 230026, China
| | - Zhiqiang Zhu
- Department of Precision Machinery and Precision Instrumentation, University of Science and Technology of China, Hefei, Anhui 230026, China
- Key Laboratory of Precision Scientific Instrumentation of Anhui Higher Education Institutes, University of Science and Technology of China, Hefei 230026, China
| | - Ting Si
- Department of Modern Mechanics, University of Science and Technology of China, Hefei, Anhui 230026, China
| | - Ronald X Xu
- Department of Precision Machinery and Precision Instrumentation, University of Science and Technology of China, Hefei, Anhui 230026, China
- Key Laboratory of Precision Scientific Instrumentation of Anhui Higher Education Institutes, University of Science and Technology of China, Hefei 230026, China
- Suzhou Institute for Advanced Research, University of Science and Technology of China, Suzhou 215123, China
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Kim HU, Lim YJ, Lee HJ, Lee NJ, Bong KW. Degassed micromolding lithography for rapid fabrication of anisotropic hydrogel microparticles with high-resolution and high uniformity. LAB ON A CHIP 2020; 20:74-83. [PMID: 31746885 DOI: 10.1039/c9lc00828d] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 05/08/2023]
Abstract
Replica molding techniques, which are used to synthesize microparticles inside anisotropic micromolds, have been developed to enable the mass production of hydrogel particles. However, these techniques are limited in their ability to synthesize only a narrow range of particle compositions and shapes because of the difficulty in loading precursors into the micromolds as well as the low particle homogeneity due to the uneven evaporation of the precursors. Herein, we describe a simple yet powerful technique, called degassed micromolding lithography, which can load precursors within 1 min regardless of the wettability. This technique is based on the gas-solubility of a degassed micromold that acts as a suction pump to completely fill the mold by drawing precursor liquids in. The semi-closed system within the micromold prevents the uneven evaporation of the precursor, which is essential for the production of homogeneous particles. Furthermore, controlled uniformity of the hydrogel microparticles (C.V. < 2%) can be achieved by engineering the design of the micromold array.
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Affiliation(s)
- Hyeon Ung Kim
- Department of Chemical and Biological Engineering, Korea University, Seoul 02841, Republic of Korea.
| | - Yong Jun Lim
- Department of Chemical and Biological Engineering, Korea University, Seoul 02841, Republic of Korea.
| | - Hyun Jee Lee
- Department of Chemical and Biological Engineering, Korea University, Seoul 02841, Republic of Korea.
| | - Nak Jun Lee
- Department of Chemical and Biological Engineering, Korea University, Seoul 02841, Republic of Korea.
| | - Ki Wan Bong
- Department of Chemical and Biological Engineering, Korea University, Seoul 02841, Republic of Korea.
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Abstract
Droplet microfluidics generates and manipulates discrete droplets through immiscible multiphase flows inside microchannels. Due to its remarkable advantages, droplet microfluidics bears significant value in an extremely wide range of area. In this review, we provide a comprehensive and in-depth insight into droplet microfluidics, covering fundamental research from microfluidic chip fabrication and droplet generation to the applications of droplets in bio(chemical) analysis and materials generation. The purpose of this review is to convey the fundamentals of droplet microfluidics, a critical analysis on its current status and challenges, and opinions on its future development. We believe this review will promote communications among biology, chemistry, physics, and materials science.
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Affiliation(s)
- Luoran Shang
- State Key Laboratory of Bioelectronics, School of Biological Science and Medical Engineering, Southeast University , Nanjing 210096, China
| | - Yao Cheng
- State Key Laboratory of Bioelectronics, School of Biological Science and Medical Engineering, Southeast University , Nanjing 210096, China
| | - Yuanjin Zhao
- State Key Laboratory of Bioelectronics, School of Biological Science and Medical Engineering, Southeast University , Nanjing 210096, China
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Wang B, Prinsen P, Wang H, Bai Z, Wang H, Luque R, Xuan J. Macroporous materials: microfluidic fabrication, functionalization and applications. Chem Soc Rev 2017; 46:855-914. [DOI: 10.1039/c5cs00065c] [Citation(s) in RCA: 106] [Impact Index Per Article: 15.1] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/19/2022]
Abstract
This article provides an up-to-date highly comprehensive overview (594 references) on the state of the art of the synthesis and design of macroporous materials using microfluidics and their applications in different fields.
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Affiliation(s)
- Bingjie Wang
- State Environmental Protection Key Laboratory of Environmental Risk Assessment and Control on Chemical Process
- School of Mechanical and Power Engineering
- East China University of Science and Technology
- Shanghai 200237
- China
| | - Pepijn Prinsen
- Departamento de Quimica Organica
- Universidad de Cordoba
- Campus de Rabanales
- Cordoba
- Spain
| | - Huizhi Wang
- School of Engineering and Physical Sciences
- Heriot-Watt University
- Edinburgh
- UK
| | - Zhishan Bai
- State Environmental Protection Key Laboratory of Environmental Risk Assessment and Control on Chemical Process
- School of Mechanical and Power Engineering
- East China University of Science and Technology
- Shanghai 200237
- China
| | - Hualin Wang
- State Environmental Protection Key Laboratory of Environmental Risk Assessment and Control on Chemical Process
- School of Mechanical and Power Engineering
- East China University of Science and Technology
- Shanghai 200237
- China
| | - Rafael Luque
- Departamento de Quimica Organica
- Universidad de Cordoba
- Campus de Rabanales
- Cordoba
- Spain
| | - Jin Xuan
- School of Engineering and Physical Sciences
- Heriot-Watt University
- Edinburgh
- UK
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Xu Y, Zhang X, Luan C, Wang H, Chen B, Zhao Y. Hybrid hydrogel photonic barcodes for multiplex detection of tumor markers. Biosens Bioelectron 2017; 87:264-270. [DOI: 10.1016/j.bios.2016.08.063] [Citation(s) in RCA: 43] [Impact Index Per Article: 6.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/07/2016] [Revised: 08/15/2016] [Accepted: 08/18/2016] [Indexed: 12/20/2022]
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Neto AI, Demir K, Popova AA, Oliveira MB, Mano JF, Levkin PA. Fabrication of Hydrogel Particles of Defined Shapes Using Superhydrophobic-Hydrophilic Micropatterns. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2016; 28:7613-7619. [PMID: 27332997 DOI: 10.1002/adma.201602350] [Citation(s) in RCA: 38] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/03/2016] [Revised: 05/30/2016] [Indexed: 06/06/2023]
Abstract
High-throughput fabrication of freestanding hydrogel particles with defined geometry and size for 3D cell culture, cell screenings, and modular tissue engineering is reported. The method employs discontinuous dewetting using superhydrophobic-hydrophilic micropatterns.
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Affiliation(s)
- Ana I Neto
- 3B's Research Group, University of Minho, Avepark - Parque de Ciência e Tecnologia, Zona Industrial da Gandra, 4805-017, Barco, GMR, Portugal
- Institute of Toxicology and Genetics, Karlsruhe Institute of Technology, Hermann-von-Helmholtz-Platz 176344, Eggenstein-Leopoldshafen, Germany
- ICVS/3B's PT Government Associate Laboratory, 4805-017, Barco, GMR, Portugal
| | - Konstantin Demir
- Institute of Toxicology and Genetics, Karlsruhe Institute of Technology, Hermann-von-Helmholtz-Platz 176344, Eggenstein-Leopoldshafen, Germany
| | - Anna A Popova
- Institute of Toxicology and Genetics, Karlsruhe Institute of Technology, Hermann-von-Helmholtz-Platz 176344, Eggenstein-Leopoldshafen, Germany
| | - Mariana B Oliveira
- 3B's Research Group, University of Minho, Avepark - Parque de Ciência e Tecnologia, Zona Industrial da Gandra, 4805-017, Barco, GMR, Portugal
- ICVS/3B's PT Government Associate Laboratory, 4805-017, Barco, GMR, Portugal
- Department of Chemistry, CICECO, University of Aveiro, Aveiro, 3810-194, Portugal
| | - João F Mano
- 3B's Research Group, University of Minho, Avepark - Parque de Ciência e Tecnologia, Zona Industrial da Gandra, 4805-017, Barco, GMR, Portugal
- ICVS/3B's PT Government Associate Laboratory, 4805-017, Barco, GMR, Portugal
- Department of Chemistry, CICECO, University of Aveiro, Aveiro, 3810-194, Portugal
| | - Pavel A Levkin
- Institute of Toxicology and Genetics, Karlsruhe Institute of Technology, Hermann-von-Helmholtz-Platz 176344, Eggenstein-Leopoldshafen, Germany.
- Karlsruhe Institute of Technology, Institute of Organic Chemistry, Karlsruhe, 76131, Germany.
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Lee GH, Sim JY, Kim SH. Polymeric Inverse Glasses for Development of Noniridescent Structural Colors in Full Visible Range. ACS APPLIED MATERIALS & INTERFACES 2016; 8:12473-12480. [PMID: 27124719 DOI: 10.1021/acsami.6b03217] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/05/2023]
Abstract
Amorphous colloidal array with short-range order displays noniridescent structural colors due to the isotropic nature of the colloidal arrangement. The low angle dependence renders the colloidal glasses, which is promising for various coloration applications. Nevertheless, the colloidal glasses are difficult to develop red structural color due to strong cavity-like resonance from individual particles in the blue region. To suppress the cavity mode and develop the colors in the full visible range, we prepare inverse glasses composed of amorphous array of air cavities with short-range order. To produce the structures in a simple and reproducible manner, monodisperse silica particles are dispersed in a photocurable resin of poly(ethylene glycol) dimethacrylate (PEGDMA) at a volume fraction of 0.3. The particles spontaneously form the amorphous array with short-range order, which is rapidly captured in polymeric films by photopolymerization of the resin. Selective removal of silica particles from the polymerized resin leaves behind amorphous array of air cavities. The inverse glasses display structural colors with negligible backscattering in blue due to short optical path and low index in each cavity. Therefore, the colors can be tuned in full visible range by simply controlling the cavity size. The photocurable suspensions of silica particles can be patterned by photolithography, which enables the production of freestanding films containing patterned inverse glasses with noniridescent structural colors.
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Affiliation(s)
- Gun Ho Lee
- Department of Chemical and Biomolecular Engineering (BK21+ Program), Korea Advanced Institute of Science and Technology (KAIST) , Daejeon 34141, Republic of Korea
| | - Jae Young Sim
- Department of Chemical and Biomolecular Engineering (BK21+ Program), Korea Advanced Institute of Science and Technology (KAIST) , Daejeon 34141, Republic of Korea
| | - Shin-Hyun Kim
- Department of Chemical and Biomolecular Engineering (BK21+ Program), Korea Advanced Institute of Science and Technology (KAIST) , Daejeon 34141, Republic of Korea
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