Strong Microcapsules with Permeable Porous Shells Made through Phase Separation in Double Emulsions

Regulation of mechanical properties of microcapsules and their applications

Microcapsules encapsulating payloads are one of the most promising delivery methods. The mechanical properties of microcapsules often determine their application scenarios. For example, microcapsules with low mechanical strength are more widely used in biomedical applications due to their superior biocompatibility, softness, and deformability. In contrast, microcapsules with high mechanical strength are often mixed into the matrix to enhance the material. Therefore, characterizing and regulating the mechanical properties of microcapsules is essential for their design optimization. This paper first outlines four methods for the mechanical characterization of microcapsules: nanoindentation technology, parallel plate compression technology, microcapillary technology, and deformation in flow. Subsequently, the mechanisms of regulating the mechanical properties of microcapsules and the progress of applying microcapsules with different degrees of softness and hardness in food, textile, and pharmaceutical formulations are discussed. These regulation mechanisms primarily include altering size and morphology, introducing sacrificial bonds, and construction of hybrid shells. Finally, we envision the future applications and research directions for microcapsules with tunable mechanical properties.

Revolutionizing targeting precision: microfluidics-enabled smart microcapsules for tailored delivery and controlled release

As promising delivery systems, smart microcapsules have garnered significant attention owing to their targeted delivery loaded with diverse active materials. By precisely manipulating fluids on the micrometer scale, microfluidic has emerged as a powerful tool for tailoring delivery systems based on potential applications. The desirable characteristics of smart microcapsules are associated with encapsulation capacity, targeted delivery capability, and controlled release of encapsulants. In this review, we briefly describe the principles of droplet-based microfluidics for smart microcapsules. Subsequently, we summarize smart microcapsules as delivery systems for efficient encapsulation and focus on target delivery patterns, including passive targets, active targets, and microfluidics-assisted targets. Additionally, based on release mechanisms, we review controlled release modes adjusted by smart membranes and on/off gates. Finally, we discuss existing challenges and potential implications associated with smart microcapsules.

Direct encapsulation of biomolecules in semi-permeable microcapsules produced with double-emulsions

Compartmentalization can serve different purposes such as the protection of biological active substances from the environment, or the creation of a unique combination of biomolecules for diagnostic, therapeutic, or other bioengineering applications. We present a method for direct encapsulation of molecules in biocompatible and semi-permeable microcapsules made from low-molecular weight poly(ethylene glycol) diacrylate (PEG-DA 258). Microcapsules are produced using a non-planar PDMS microfluidic chip allowing for one-step production of water-in-PEG-DA 258-in-water double-emulsions, which are polymerized with UV light into a poly-PEG-DA 258 shell. Semi-permeable microcapsules are obtained by adding an inert solvent to the PEG-DA 258. Due to the favorable hydrophilicity of poly-PEG-DA 258, proteins do not adsorb to the capsule shell, and we demonstrate the direct encapsulation of enzymes, which can also be dried in the capsules to preserve activity. Finally, we leverage capsule permeability for the implementation of a two-layer communication cascade using compartmentalized DNA strand displacement reactions. This work presents the direct encapsulation of active biomolecules in semi-permeable microcapsules, and we expect our platform to facilitate the development of artificial cells and generating encapsulated diagnostics or therapeutics.

Manufacturing polymeric porous capsules

Polymeric porous capsules represent hugely promising systems that allow a size-selective through-shell material exchange with their surroundings. They have vast potential in applications ranging from drug delivery and chemical microreactors to artificial cell science and synthetic biology. Due to their porous core-shell structure, polymeric porous capsules possess an enhanced permeability that enables the exchange of small molecules while retaining larger compounds and macromolecules. The cross-capsule transfer of material is regulated by their pore size cut-off, which depends on the molecular composition and adopted fabrication method. This review outlines the main strategies for manufacturing polymeric porous capsules and provides some practical guidance for designing polymeric capsules with controlled pore size.

Self-Grown Bacterial Cellulose Capsules Made through Emulsion Templating

Microcapsules made of synthetic polymers are used for the release of cargo in agriculture, food, and cosmetics but are often difficult to be degraded in the environment. To diminish the environmental impact of microcapsules, we use the biofilm-forming ability of bacteria to grow cellulose-based biodegradable microcapsules. The present work focuses on the design and optimization of self-grown bacterial cellulose capsules. In contrast to their conventionally attributed pathogenic role, bacteria and their self-secreted biofilms represent a multifunctional class of biomaterials. The bacterial strain used in this work, Gluconacetobacter xylinus, is able to survive and proliferate in various environmental conditions by forming biofilms as part of its lifecycle. Cellulose is one of the main components present in these self-secreted protective layers and is known for its outstanding mechanical properties. Provided enough nutrients and oxygen, these bacteria and the produced cellulose are able to self-assemble at the interface of any given three-dimensional template and could be used as a novel stabilization concept for water-in-oil emulsions. Using a microfluidic setup for controlled emulsification, we demonstrate that bacterial cellulose capsules can be produced with tunable size and monodispersity. Furthermore, we show that successful droplet stabilization and bacterial cellulose formation are functions of the bacteria concentration, droplet size, and surfactant type. The obtained results represent the first milestone in the production of self-assembled biodegradable cellulose capsules to be used in a vast range of applications such as flavor, fragrance, agrochemicals, nutrients, and drug encapsulation.

Ordered Mesoporous Microcapsules from Double Emulsion Confined Block Copolymer Self-Assembly

Polymeric microcapsules with shells containing homogeneous pores with uniform diameter on the nanometer scale are reported. The mesoporous microcapsules are obtained from confined self-assembly of amphiphilic block copolymers with a selective porogen in the shell of water-in-oil-in-water double emulsion drops. The use of double emulsion drops as a liquid template enables the formation of homogeneous capsules of 100s of microns in diameter, with aqueous cores encapsulated in a shell membrane with a tunable thickness of 100s of nanometers to 10s of microns. Microcapsules with shells that exhibit an ordered gyroidal morphology and three-dimensionally connected mesopores are obtained from the triblock terpolymer poly(isoprene)-block-poly(styrene)-block-poly(4-vinylpyridine) coassembled with pentadecylphenol as a porogen. The bicontinuous shell morphology yields nanoporous paths connecting the inside to the outside of the microcapsule after porogen removal; by contrast, one-dimensional hexagonally packed cylindrical pores, obtained from a traditional diblock copolymer system with parallel alignment to the surface, would block transport through the shell. To enable the mesoporous microcapsules to withstand harsh conditions, such as exposure to organic solvents, without rupture of the shell, we develop a cross-linking method of the nanostructured triblock terpolymer shell after its self-assembly. The microcapsules exhibit pH-responsive permeability to polymeric solutes, demonstrating their potential as a filtration medium for actively tunable macromolecular separation and purification. Furthermore, we report a tunable dual-phase separation method to fabricate microcapsules with hierarchically porous shells that exhibit ordered mesoporous membrane walls within sponge-like micron-sized macropores to further control shell permeability.

Microfluidic Fabrication of Phase-Inverted Microcapsules with Asymmetric Shell Membranes with Graded Porosity

Microcapsules with liquid cores and solid shells are attractive as dispersible protective micron-sized containers. Applications that rely on molecular mass transport often require a combination of size selectivity, high permeability, and mechanical stability. Capsule architectures that combine all these features represent a material property, design, and fabrication challenge. In this work, the design of an asymmetric microcapsule shell architecture is reported to achieve a good combination of the desired features. Poly(methyl methacrylate) phase-inverted microcapsules featuring an asymmetric graded macroporous shell covered with a dense skin separation layer are obtained from water-in-oil-in-water double emulsion drops that are phase-inverted in a water-based coagulation bath. The phase-inverted microcapsules exhibit good mechanical stability and allow for high permeability of its shell membrane with molecular size dependence.

Controllable Fabrication of Inhomogeneous Microcapsules for Triggered Release by Osmotic Pressure

Inhomogeneous microcapsules that can encapsulate various cargo for controlled release triggered by osmotic shock are designed and reported. The microcapsules are fabricated using a microfluidic approach and the inhomogeneity of shell thickness in the microcapsules can be controlled by tuning the flow rate ratio of the middle phase to the inner phase. This study demonstrates the swelling of these inhomogeneous microcapsules begins at the thinnest part of shell and eventually leads to rupture at the weak spot with a low osmotic pressure. Systematic studies indicate the rupture fraction of these microcapsules increases with increasing inhomogeneity, while the rupture osmotic pressure decreases linearly with increasing inhomogeneity. The inhomogeneous microcapsules are demonstrated to be impermeable to small probe molecules, which enables long-term storage. Thus, these microcapsules can be used for long-term storage of enzymes, which can be controllably released through osmotic shock without impairing their biological activity. The study provides a new approach to design effective carriers to encapsulate biomolecules and release them on-demand upon applying osmotic shock.

The Horizon of the Emulsion Particulate Strategy: Engineering Hollow Particles for Biomedical Applications

With their hierarchical structures and the substantial surface areas, hollow particles have gained immense research interest in biomedical applications. For scalable fabrications, emulsion-based approaches have emerged as facile and versatile strategies. Here, the recent achievements in this field are unfolded via an "emulsion particulate strategy," which addresses the inherent relationship between the process control and the bioactive structures. As such, the interior architectures are manipulated by harnessing the intermediate state during the emulsion revolution (intrinsic strategy), whereas the external structures are dictated by tailoring the building blocks and solidification procedures of the Pickering emulsion (extrinsic strategy). Through integration of the intrinsic and extrinsic emulsion particulate strategy, multifunctional hollow particles demonstrate marked momentum for label-free multiplex detections, stimuli-responsive therapies, and stem cell therapies.

Construction of polyporous polymer microspheres with a tailored mesoporous wall

Polymer microspheres with a novel hierarchically porous structure (inner macropores and a mesoporous wall) were fabricated by taking advantage of γ-ray-radiation-initiated dispersion polymerization.

Preparation of Hollow Cu and CuO x Microspheres with a Hierarchical Structure for Heterogeneous Catalysis

Diffusion is one of the most critical factors which affect the performance of porous catalysts in heterogeneous reactions. Hollow spheres with a hierarchical structure could significantly improve the mass transfer in the spherical catalyst. Therefore, preparation of such kind of microspheres is an important work in the field of inorganic synthesis. Herein, we combine microfluidic technology and electroless deposition to prepare hollow Cu and CuO _x microspheres with a hierarchically porous structure. These microspheres have a controllable diameter (100-500 μm) and shell thickness (10-60 μm). Numerical simulation and experimental results indicate that the hollow structure is beneficial for the diffusion and utilization of the catalyst in heterogeneous reactions. The Cu and CuO _x microspheres were used to catalyze the hydrogenation and Fenton-like reactions in a flow reactor, respectively. The conversion of all reactants can reach more than 95%, and catalysts can maintain their reactivity in long reaction times. Thus, the strategy in the present research should apply in the construction of other porous catalysts with high performance.

Communication and quorum sensing in non-living mimics of eukaryotic cells

Cells in tissues or biofilms communicate with one another through chemical and mechanical signals to coordinate collective behaviors. Non-living cell mimics provide simplified models of natural systems; however, it has remained challenging to implement communication capabilities comparable to living cells. Here we present a porous artificial cell-mimic containing a nucleus-like DNA-hydrogel compartment that is able to express and display proteins, and communicate with neighboring cell-mimics through diffusive protein signals. We show that communication between cell-mimics allows distribution of tasks, quorum sensing, and cellular differentiation according to local environment. Cell-mimics can be manufactured in large quantities, easily stored, chemically modified, and spatially organized into diffusively connected tissue-like arrangements, offering a means for studying communication in large ensembles of artificial cells.

Cells communicate through chemical and mechanical signals but emulating these in non-living mimics has been challenging. Here the authors present a porous mimic with a DNA-hydrogel ‘nucleus’ that can communicate through diffusive protein signals.

Self-Assembly of TiO2 Nanofiber-Based Microcapsules by Spontaneously Evolved Multiple Emulsions

We demonstrate hierarchical nest/crust-like colloidosomes composed of interlocked titanium dioxide (TiO₂) nanofibers using spontaneously evolved n-butanol/water/ n-butanol (B/W/B) emulsions. We find two mechanisms to produce colloidosomes from B/W/B droplets due to their mutual solubility and dewetting discrepancy. Porous TiO₂ colloidal capsules with loosely intertwined nanofibers were obtained after the dewetting of nanofiber-coated B/W/B droplets, while crustlike TiO₂ colloidosomes with a thin shell and large hollow interior are developed from amphiphilic polymer-stabilized B/W/B droplets. We further investigate the effect of experimental parameters, including the initial droplet size, the nanofiber concentration, and the water/butanol ratios in butanol phases, on the droplet-to-colloidosome evolution and resultant morphology of colloidosomes. Our simple and versatile approach for fabricating TiO₂ colloidosomes can be extended to a range of irregular colloidal particles, and the products have great potential to act as host systems in electrochemical catalysis, photothermal therapy, or filtration materials.

Strong Dual-Compartment Microcapsules Loaded with High Cargo Contents

Compartmentalized microcapsules are useful for the release of multiple cargos in medicine, agriculture, and advanced responsive materials. Although several encapsulation strategies that involve more than one cargo have been proposed, dual- or multicompartment capsules with high cargo loadings and sufficient mechanical stability are rarely reported. Here, we propose a single-step emulsification route for the preparation of strong dual-compartment capsules that can host the main cargo in their core in combination with another liquid cargo stored within their thick shell. Capsules are produced through the polymerization of the middle oil phase of water-oil-water double emulsions made by microfluidics. Compartmentalization results from the phase separation of monomers within the middle phase of the double emulsion. We investigate the effect of such phase separation process on the microstructure and mechanical properties of the capsules and eventually illustrate the potential of this approach by creating thermosensitive capsules with programmable bursting temperature. The large variety of possible mixtures of monomers and cargos that can be added in the oil and aqueous phases of the double emulsion templates makes this encapsulation approach a promising route for the fabrication of robust microcapsules for on-demand release of multiple cargos.

One-Step Bulk Fabrication of Polymer-Based Microcapsules with Hard-Soft Bilayer Thick Shells

Microcapsules are important for the protection, transport, and delivery of cargo in a variety of fields but are often too weak to withstand the high mechanical stresses that arise during the preparation and formulation of products. Although thick-shell strong capsules have been developed to circumvent this issue, the microfluidic or multistep methods utilized thus far limit the ease of fabrication and encapsulation throughput. Here, we exploit the phase separation of ternary liquid mixtures to achieve a high-throughput fabrication of strong bilayer microcapsules using a one-step bulk emulsification process. Phase separation is induced by the diffusion of water from the continuous phase into droplets that initially contain a mixture of monomers, cross-linkers, an initiator, and cosolvent γ-butyrolactone. The double emulsions generated via such a phase separation are converted into microcapsules through a polymerization reaction triggered by UV illumination. Surprisingly, the shells of the consolidated capsules exhibit a hard-soft bilayer structure that can be designed to show a resilient eggshell-like fracture behavior. Our method allows for the production of large volumes of microcapsules with such a strong bilayer shell within a time scale of only a few minutes, thus offering an enticing pathway toward the high-throughput fabrication of mechanically robust encapsulation systems.

Pickering Emulsions Stabilized by pH-Responsive Microgels and Their Scalable Transformation to Robust Submicrometer Colloidoisomes with Selective Permeability

Colloidosomes are micrometer-sized hollow particles that have shells consisting of coagulated or fused colloid particles. While many large colloidosomes with sizes well above 1.0 μm have been prepared, there are fewer examples of submicrometer colloidosomes. Here, we establish a simple emulsion templating-based method for the preparation of robust submicrometer pH-responsive microgel colloidosomes. The colloidosomes are constructed from microgel particles based on ethyl acrylate and methacrylic acid with peripheral vinyl groups. The pH-responsive microgels acted as both a Pickering emulsion stabilizer and macro-cross-linker. The emulsion formation studies showed that the minimum droplet diameter was reached when the microgel particles were partially swollen. Microgel colloidosomes were prepared by covalently interlinking the microgels adsorbed at the oil-water interface using thermal free-radical coupling. The colloidosomes were prepared using a standard high-shear mixer with two different rotor sizes that corresponded to high shear (HS) and very high shear (VHS) mixing conditions. The latter enabled the construction of submicrometer pH-responsive microgel-colloidosomes on the gram scale. The colloidosomes swelled strongly when the pH increased to above 6.0. The colloidosomes were robust and showed no evidence of colloidosome breakup at high pH. The effect of solute size on shell permeation was studied using a range of FITC-dextran polymers, and size-selective permeation occurred. The average pore size of the VHS microgel-colloidosomes was estimated to be between 6.6 and 9.0 nm at pH 6.2. The microgel-colloidosome properties suggest that they have the potential for future applications in cosmetics, photonics, and delivery.