Multiphase Microfluidics: Fundamentals, Fabrication, and Functions

Microfluidic strategies for engineering oxygen-releasing biomaterials

In the field of tissue engineering, local hypoxia in large-cell structures (larger than 1 mm3) poses a significant challenge. Oxygen-releasing biomaterials supply an innovative solution through oxygen ⁠ delivery in a sustained and controlled manner. Compared to traditional methods such as emulsion, sonication, and agitation, microfluidic technology offers distinct benefits for oxygen-releasing material production, including controllability, flexibility, and applicability. It holds enormous potential in the production of smart oxygen-releasing materials. This review comprehensively covers the fabrication and application of microfluidic-enabled oxygen-releasing biomaterials. To begin with, the physical mechanism of various microfluidic technologies and their differences in oxygen carrier preparation are explained. Then, the distinctions among diverse oxygen-releasing components in regards for oxygen-releasing mechanism, oxygen-carrying capacity, and duration of oxygen release are presented. Finally, the present obstacles and anticipated development trends are examined together with the application outcomes of oxygen-releasing biomaterials based on microfluidic technology in the biomedical area. STATEMENT OF SIGNIFICANCE: Oxygen is essential for sustaining life, and hypoxia (a condition of low oxygen) is a significant challenge in various diseases. Microfluidic-based oxygen-releasing biomaterials offer precise control and outstanding performance, providing unique advantages over traditional approaches for tissue engineering. However, comprehensive reviews on this topic are currently lacking. In this review, we provide a comprehensive analysis of various microfluidic technologies and their applications for developing oxygen-releasing biomaterials. We compare the characteristics of organic and inorganic oxygen-releasing biomaterials and highlight the latest advancements in microfluidic-enabled oxygen-releasing biomaterials for tissue engineering, wound healing, and drug delivery. This review may hold the potential to make a significant contribution to the field, with a profound impact on the scientific community.

Self-Assembly Pathways of Triblock Janus Particles into 3D Open Lattices

The self-assembly of triblock Janus particles is simulated from a fluid to 3D open lattices: pyrochlore, perovskite, and diamond. The coarse-grained model explicitly takes into account the chemical details of the Janus particles (attractive patches at the poles and repulsion around the equator) and it contains explicit solvent particles. Hydrodynamic interactions are accounted for by dissipative particle dynamics. The relative stability of the crystals depends on the patch width. Narrow, intermediate, and wide patches stabilize the pyrochlore-, the perovskite-, and the diamond-lattice, respectively. The nucleation of all three lattices follows a two-step mechanism: the particles first agglomerate into a compact and disordered liquid cluster, which does not crystallize until it has grown to a threshold size. Second, the particles reorient inside this cluster to form crystalline nuclei. The free-energy barriers for the nucleation of pyrochlore and perovskite are ≈10 kBT, which are close to the nucleation barriers of previously studied 2D kagome lattices. The barrier height for the nucleation of diamond, however, is much larger (>20 kBT), as the symmetry of the triblock Janus particles is not perfect for a diamond structure. The large barrier is associated with the reorientation of particles, i.e., the second step of the nucleation mechanism.

Free-Boundary Microfluidic Platform for Advanced Materials Manufacturing and Applications

Microfluidics, with its remarkable capacity to manipulate fluids and droplets at the microscale, has emerged as a powerful platform in numerous fields. In contrast to conventional closed microchannel microfluidic systems, free-boundary microfluidic manufacturing (FBMM) processes continuous precursor fluids into jets or droplets in a relatively spacious environment. FBMM is highly regarded for its superior flexibility, stability, economy, usability, and versatility in the manufacturing of advanced materials and architectures. In this review, a comprehensive overview of recent advancements in FBMM is provided, encompassing technical principles, advanced material manufacturing, and their applications. FBMM is categorized based on the foundational mechanisms, primarily comprising hydrodynamics, interface effects, acoustics, and electrohydrodynamic. The processes and mechanisms of fluid manipulation are thoroughly discussed. Additionally, the manufacturing of advanced materials in various dimensions ranging from zero-dimensional to three-dimensional, as well as their diverse applications in material science, biomedical engineering, and engineering are presented. Finally, current progress is summarized and future challenges are prospected. Overall, this review highlights the significant potential of FBMM as a powerful tool for advanced materials manufacturing and its wide-ranging applications.

Nanoparticle Assembly: From Self-Organization to Controlled Micropatterning for Enhanced Functionalities

Nanoparticles form long-range micropatterns via self-assembly or directed self-assembly with superior mechanical, electrical, optical, magnetic, chemical, and other functional properties for broad applications, such as structural supports, thermal exchangers, optoelectronics, microelectronics, and robotics. The precisely defined particle assembly at the nanoscale with simultaneously scalable patterning at the microscale is indispensable for enabling functionality and improving the performance of devices. This article provides a comprehensive review of nanoparticle assembly formed primarily via the balance of forces at the nanoscale (e.g., van der Waals, colloidal, capillary, convection, and chemical forces) and nanoparticle-template interactions (e.g., physical confinement, chemical functionalization, additive layer-upon-layer). The review commences with a general overview of nanoparticle self-assembly, with the state-of-the-art literature review and motivation. It subsequently reviews the recent progress in nanoparticle assembly without the presence of surface templates. Manufacturing techniques for surface template fabrication and their influence on nanoparticle assembly efficiency and effectiveness are then explored. The primary focus is the spatial organization and orientational preference of nanoparticles on non-templated and pre-templated surfaces in a controlled manner. Moreover, the article discusses broad applications of micropatterned surfaces, encompassing various fields. Finally, the review concludes with a summary of manufacturing methods, their limitations, and future trends in nanoparticle assembly.

Microfluidic Printing of Vertically-Oriented Nanosheets/MOFs Hetero-Interface for Intensive Pseudocapacitive Storage

Efficient manufacture of electroactive vertically-oriented nanosheets with enhanced electrolyte mass diffusion and strong interfacial redox dynamics is critical for realizing high energy density of miniature supercapacitor (SC), but still challenging. Herein, microfluidic droplet printing is developed to controllably construct vertically-oriented graphene/ZIF-67 hetero-microsphere (VAGS/ZIF-67), where the ZIF-67 is coordinately grown on vertically-oriented graphene framework via Co─O─C bonds. The VAGS/ZIF-67 shows ordered porous channel, high electroactivity and strong interfacial interaction, providing rapid electrolyte diffusion dynamics and high faradaic capacitance in KOH solution (1674 F g-1 , 1004 C g-1 ), which are verified by computational fluid dynamics (CFD) and density functional theory (DFT). Moreover, the VAGS/ZIF-67 based SC exhibits large energy density (100 Wh kg-1 ), excellent durability (10 000 cycles and high/low temperature), and robust power-supply applications in portable electronics.

Recent Trends of Microfluidics in Food Science and Technology: Fabrications and Applications

The development of novel materials with microstructures is now a trend in food science and technology. These microscale materials may be applied across all steps in food manufacturing, from raw materials to the final food products, as well as in the packaging, transport, and storage processes. Microfluidics is an advanced technology for controlling fluids in a microscale channel (1~100 μm), which integrates engineering, physics, chemistry, nanotechnology, etc. This technology allows unit operations to occur in devices that are closer in size to the expected structural elements. Therefore, microfluidics is considered a promising technology to develop micro/nanostructures for delivery purposes to improve the quality and safety of foods. This review concentrates on the recent developments of microfluidic systems and their novel applications in food science and technology, including microfibers/films via microfluidic spinning technology for food packaging, droplet microfluidics for food micro-/nanoemulsifications and encapsulations, etc.

Microfluidic Methods in Janus Particle Synthesis

Janus particles have been at the center of attention over the years due to their asymmetric nature that makes them superior in many ways to conventional monophase particles. Several techniques have been reported for the synthesis of Janus particles; however, microfluidic-based techniques are by far the most popular due to their versatility, rapid prototyping, low reagent consumption and superior control over reaction conditions. In this review, we will go through microfluidic-based Janus particle synthesis techniques and highlight how recent advances have led to complex functionalities being imparted to the Janus particles.

Two-Dimensional Hybrid Nanosheet-Based Supercapacitors: From Building Block Architecture, Fiber Assembly, and Fabric Construction to Wearable Applications

Fiber-based supercapacitors (F-SCs) have inspired widespread interest in the fields of wearable technology, energy, and carbon neutralization due to their highly deformable flexibility, fast charging/discharging capability, long-term stability, and energy conservation ability. In this review, we summarize the latest developments for fabricating fibrous electrodes of F-SCs where advanced micro two-dimensional (2D) building blocks (e.g., MXene and graphene) are chemically assembled and constructed into ordered mesofibers and multifunctional macrofabrics. Diverse fundamental principles of 2D hybrid nanosheets with respect to surface controls, pseudocapacitive modifications, and microstructural manipulations, promoting rapid electron transfer and charge conduction, are introduced. Additionally, various spinning methods for assembling and fabricating sophisticated fibers with advanced nano/microstructures, including hierarchical skeletons, anisotropic backbones, surface/entire porous frameworks, and vertical-aligned networks, for boosting ionic kinetic transport/storage are presented. Likewise, the structure-activity relationships between the porous structure and electrochemical performance are clarified. Moreover, multifunctional fabrics in terms of high flexibilities/strengths, superior electrical conductivities, and stabilized operations, which realize large energy density, deformable capability, and robust stability under harsh conditions, are emphasized. In particular, the potential power-supply applications, including flexible electronic devices, self-powered functions, and energy-sensor systems, are highlighted. Finally, a short conclusion and outlook, along with the current challenges and future opportunities of next-generation F-SCs, are proposed.

Enzyme Cascade Reaction Propelled Multicompartmental Colloidal Motors

Compartmentalization is a crucial natural methodology to enable multiple biocatalytic transformations to proceed efficiently. Herein, we report a biocompatible multicompartmental colloidal motor that can achieve autonomous movement in the biological environment through two-enzyme cascade reactions of immobilized enzymes. The colloidal motors with the heterogeneous multicompartment structure were prepared in one step by microfluidic technology, and the compartmentalized encapsulation of glucose oxidase (GOD) and catalase (CAT) was realized. The fabricated colloidal motor was size controllable by tuning the flow rates of the microfluidic system, and its autonomous movement can be triggered by good responsiveness to the alkaline environment. In glucose medium of pH 7.5, the pH-responsive alginate cores of the colloidal motor swell to facilitate fuel penetration and enzyme-catalyzed reactions. The enzyme cascade between GOD and CAT immobilized in the colloidal motor chamber results in the self-propulsion of the colloid motor in glucose medium. The compartmentalized encapsulation of immobilized enzyme improves the stability of the enzyme and enables multicompartmental colloidal motors to self-propel in an alkaline intestinal environment through an enzyme cascade reaction. These features indicate that such multicompartmental colloidal motors actuated by enzyme cascade reaction in biocompatible fuel have great potential for co-encapsulation and autonomous movement in different applications.

Recyclable cooperative catalyst for accelerated hydroaminomethylation of hindered amines in a continuous segmented flow reactor

Synthesis of hindered amines using the atom-efficient hydroaminomethylation (HAM) route remains a challenge. Here, we report a general and accelerated HAM in segmented flow, achieved via a cooperative effect between rhodium (Rh)/N-Xantphos and a co-catalyst (2-Fluoro-4-methylbenzoic acid) to increase the reactivity by 70 fold when compared to Rh/Xantphos in batch reactors. The cooperation between Rh and the co-catalyst facilitates the cleavage of the H–H bond and drives the equilibrium-limited condensation step forward. Online reaction optimization expands the scope to include alkyl, aryl, and primary amines. In-flow solvent tuning enables selectivity switching from amine to enamine without the need for changing the ligand. Furthermore, leveraging the ionic nature of the catalyst, we present a robust Rh recovery strategy up to 4 recycles without loss of activity.

Flow chemistry enables intensified production of hindered amines. Here the authors present a rapid and reusable catalyst to operate in a segmented flow reactor for olefin hydroaminomethylation to selectively produce hindered amines or enamines.

Advanced oxidation processes in microreactors for water and wastewater treatment: Development, challenges, and opportunities

The miniaturization of reaction processes by microreactors offers many significant advantages over the use of larger, conventional reactors. Microreactors' interior structures exhibit comparatively higher surface area-to-volume ratios, which reduce reactant diffusion distances, enable faster and more efficient heat and mass transfer, and better control over process conditions. These advantages can be exploited to significantly enhance the performance of advanced oxidation processes (AOPs) commonly used for the removal of water pollutants. This comprehensive review of the rapidly emerging area of environmental microfluidics describes recent advances in the development and application of microreactors to AOPs for water and wastewater treatment. Consideration is given to the hydrodynamic properties, construction materials, fabrication techniques, designs, process features, and upscaling of microreactors used for AOPs. The use of microreactors for various AOP types, including photocatalytic, electrochemical, Fenton, ozonation, and plasma-phase processes, showcases how microfluidic technology enhances mass transfer, improves treatment efficiency, and decreases the consumption of energy and chemicals. Despite significant advancements of microreactor technology, organic pollutant degradation mechanisms that operate during microscale AOPs remain poorly understood. Moreover, limited throughput capacity of microreactor systems significantly restrains their industrial-scale applicability. Since large microreactor-inspired AOP systems are needed to meet the high-throughput requirements of the water treatment sector, scale-up strategies and recommendations are suggested as priority research opportunities. While microstructured reactor technology remains in an early stage of development, this work offers valuable insight for future research and development of AOPs in microreactors for environmental purposes.

Numerical analysis on the effects of microfluidic-based bioprinting parameters on the microfiber geometrical outcomes

The application of microfluidics technology in additive manufacturing is an emerging approach that makes possible the fabrication of functional three-dimensional cell-laden structured biomaterials. A key challenge that needs to be addressed using a microfluidic-based printhead (MBP) is increasing the controllability over the properties of the fabricated microtissue. Herein, an MBP platform is numerically simulated for the fabrication of solid and hollow microfibers using a microfluidic channel system with high level of controllability over the microfiber geometrical outcomes. Specifically, the generation of microfibers is enabled by studying the effects of microfluidic-based bioprinting parameters that capture the different range of design, bioink material, and process parameter dependencies as numerically modeled as a multiphysics problem. Furthermore, the numerical model is verified and validated, exhibiting good agreement with literature-derived experimental data in terms of microfiber geometrical outcomes. Additionally, a predictive mathematical formula that correlates the dimensionless process parameters with dimensionless geometrical outcomes is presented to calculate the geometrical outcomes of the microfibers. This formula is expected to be applicable for bioinks within a prescribed range of the density and viscosity value. The MBP applications are highlighted towards precision fabrication of heterogeneous microstructures with functionally graded properties to be used in organ generation, disease modeling, and drug testing studies.

Microfluidic-based functional materials: new prospects for wound healing and beyond

Microfluidics has been applied to fabricate high-performance functional materials contributing to all physiological stages of wound healing. The advances of microfluidic-based functional materials for wound healing have been summarized.

Microfluidic Network Simulations Enable On-Demand Prediction of Control Parameters for Operating Lab-on-a-Chip-Devices

Reliable operation of lab-on-a-chip systems depends on user-friendly, precise, and predictable fluid management tailored to particular sub-tasks of the microfluidic process protocol and their required sample fluids. Pressure-driven flow control, where the sample fluids are delivered to the chip from pressurized feed vessels, simplifies the fluid management even for multiple fluids. The achieved flow rates depend on the pressure settings, fluid properties, and pressure-throughput characteristics of the complete microfluidic system composed of the chip and the interconnecting tubing. The prediction of the required pressure settings for achieving given flow rates simplifies the control tasks and enables opportunities for automation. In our work, we utilize a fast-running, Kirchhoff-based microfluidic network simulation that solves the complete microfluidic system for in-line prediction of the required pressure settings within less than 200 ms. The appropriateness of and benefits from this approach are demonstrated as exemplary for creating multi-component laminar co-flow and the creation of droplets with variable composition. Image-based methods were combined with chemometric approaches for the readout and correlation of the created multi-component flow patterns with the predictions obtained from the solver.

Direct Measurement of Minimum Miscibility Pressure of Decane and CO2 in Nanoconfined Channels

Determining gas and oil minimum miscibility pressure (MMP) plays a vital role in the enhanced oil recovery. Injecting gases above the MMP into oil reservoirs leads to a relatively high oil recovery ratio. For conventional reservoirs, the fluid bulk MMP is measured by lab techniques such as the rising bubble approach. However, for the increasingly important tight and shale reservoirs, oil is confined in nanoscale pores. Nanoscopic MMP remains largely unknown from experiments and relies heavily on theoretical predictions. To close this gap, we developed a nanofluidic device to determine the MMP down to 50 nm by measuring the fluorescence intensity change in a nanoconfined channel. CO₂ and decane are used as the working fluids, with 1% fluorescent dye for characterization. At the isothermal condition, the fluorescence intensity in decane reduces with the injecting CO₂ pressure increasing, and the maximum fluorescence intensity reduction at certain CO₂ pressure indicates the MMP being reached. We measured and compared CO₂ and decane MMP at the bulk scale (5 μm) and nanoscale (50 nm). The experimental results align well with literature data and theoretical predictions. Importantly, our nanofluidic approach provides a promising strategy to determine the nanoscopic fluid MMP and is readily applicable in assisting the enhanced tight/shale oil recovery.

How electrospray potentials can disrupt droplet microfluidics and how to prevent this

A pressure-resistant microfluidic glass chip that integrates a packed-bed HPLC column, a droplet generator and a monolithic electrospray emitter is presented. This approach enables a seamless coupling of chip-HPLC and droplet microfluidics with ESI-MS detection. For the electrical contacting of the emitter, an electrode was integrated into the channel, which reaches up to the emitter tip. The incidental finding that under certain circumstances, the electrospray potential can strongly disturb the droplet microfluidics by electrowetting, was investigated in detail. Strategies to avoid this are evaluated and include electrical shielding and/or chip layouts, where the droplet generator is positioned at a long distance from the emitter.

Enhanced single-cell encapsulation in microfluidic devices: From droplet generation to single-cell analysis

Single-cell analysis to investigate cellular heterogeneity and cell-to-cell interactions is a crucial compartment to answer key questions in important biological mechanisms. Droplet-based microfluidics appears to be the ideal platform for such a purpose because the compartmentalization of single cells into microdroplets offers unique advantages of enhancing assay sensitivity, protecting cells against external stresses, allowing versatile and precise manipulations over tested samples, and providing a stable microenvironment for long-term cell proliferation and observation. The present Review aims to give a preliminary guidance for researchers from different backgrounds to explore the field of single-cell encapsulation and analysis. A comprehensive and introductory overview of the droplet formation mechanism, fabrication methods of microchips, and a myriad of passive and active encapsulation techniques to enhance single-cell encapsulation efficiency were presented. Meanwhile, common methods for single-cell analysis, especially for long-term cell proliferation, differentiation, and observation inside microcapsules, are briefly introduced. Finally, the major challenges faced in the field are illustrated, and potential prospects for future work are discussed.

Redox-Driven Spontaneous Double Emulsion

The formation of spontaneous double emulsions is a peculiar phenomenon in emulsion systems. When compared to the traditional one-step and two-step methods for preparing double emulsions, spontaneous emulsification can not only steadily load uniform water droplets into an oil phase, but can also facilitate the preparation of emulsions with higher stability. However, the limited solubility of salts, which are typically used to modify osmotic pressure, in organic oils has inhibited the viability of this method for the preparation of W/O/W double emulsions. In this paper, a redox-driven spontaneous emulsification method is developed and investigated. Instead of employing oil-soluble salts, an oxidation reaction is implemented in the oil phase, which produces cation radicals and iodide counterions to generate osmotic pressure. Additionally, amphiphilic polymer chains are harnessed as stabilizers for the newly formed W/O interfaces. Various characterization methods have been used to elucidate the mechanism of both the oxidation reaction and the spontaneous formation of double emulsions.