Controllable preparation of monodisperse O/W and W/O emulsions in the same microfluidic device

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.

Application of NIRs coupled with PLS and ANN modelling to predict average droplet size in oil-in-water emulsions prepared with different microfluidic devices

In this study, the potential of microfluidic systems with different microchannel geometries (microchannel with teardrop micromixers and microchannel with swirl micromixers) for the preparation of oil-in-water (O/W) emulsions using two different emulsifiers (2 % and 4 % Tween 20 and 2% and 4 % PEG 2000) at total flow rates of 20-280 μL/min was investigated. The results showed that droplets with a smaller average Feret diameter were obtained when a microfluidic device with tear drop micromixers was used. To predict the average Feret diameter of O/W emulsion droplets, near-infrared (NIR) spectra of all prepared emulsions were collected and coupled with partial least squares (PLS) regression and artificial neural network modelling (ANN). The results showed that PLS models based on NIR spectra can ensure acceptable qualitative prediction, while highly non-linear ANN models are more suitable for predicting the average Feret diameter of O/W droplets. High R² values (R²_validation greater than 0.8) confirm that ANNs can be used to monitor the emulsification process.

Materials and methods for droplet microfluidic device fabrication

Since the first reports two decades ago, droplet-based systems have emerged as a compelling tool for microbiological and (bio)chemical science, with droplet flow providing multiple advantages over standard single-phase microfluidics such as removal of Taylor dispersion, enhanced mixing, isolation of droplet contents from surfaces, and the ability to contain and address individual cells or biomolecules. Typically, a droplet microfluidic device is designed to produce droplets with well-defined sizes and compositions that flow through the device without interacting with channel walls. Successful droplet flow is fundamentally dependent on the microfluidic device - not only its geometry but moreover how the channel surfaces interact with the fluids. Here we summarise the materials and fabrication techniques required to make microfluidic devices that deliver controlled uniform droplet flow, looking not just at physical fabrication methods, but moreover how to select and modify surfaces to yield the required surface/fluid interactions. We describe the various materials, surface modification techniques, and channel geometry approaches that can be used, and give examples of the decision process when determining which material or method to use by describing the design process for five different devices with applications ranging from field-deployable chemical analysers to water-in-water droplet creation. Finally we consider how droplet microfluidic device fabrication is changing and will change in the future, and what challenges remain to be addressed in the field.

Fabrication of Microfiber-Templated Microfluidic Chips with Microfibrous Channels for High Throughput and Continuous Production of Nanoscale Droplets

A polydimethylsiloxane (PDMS) microfluidic chip with well-interconnected microfibrous channels was fabricated by using an electrospun poly(ε-caprolactone) (PCL) microfibrous matrix and 3D-printed pattern as templates. The microfiber-templated microfluidic chip (MTMC) was used to produce nanoscale emulsions and spheres through multiple emulsification at many small micro-orifice junctions among microfibrous channels. The emulsion formation mechanisms in the MTMC were the cross-junction dripping or Y-junction splitting at the micro-orifice junctions. We demonstrated the high throughput and continuous production of water-in-oil emulsions and polyethylene glycol-diacrylate (PEG-DA) spheres with controlled size ranges from 2.84 μm to 83.6 nm and 1.03 μm to 45.7 nm, respectively. The average size of the water droplets was tuned by changing the micro-orifice diameter of the MTMC and the flow rate of the continuous phase. The MTMC theoretically produced 58 trillion PEG-DA nanospheres per hour without high shear force. In addition, we demonstrated the higher encapsulation efficiency of the PEG-DA microspheres in the MTMC than that of the microspheres fabricated by ultrasonication. The MTMC can be used as a powerful platform for the large-scale and continuous productions of emulsions and spheres.

Droplet microfluidics-based biomedical microcarriers

Droplet microfluidic technology provides a new platform for controllable generation of microdroplets and droplet-derived materials. In particular, because of the ability in high-throughput production and accurate control of the size, structure, and function of these materials, droplet microfluidics presents unique advantages in the preparation of functional microcarriers, i.e., microsized liquid containers or solid particles that serve as substrates of biomolecules or cells. These microcarriers could be extensively applied in the areas of cell culture, tissue engineering, and drug delivery. In this review, we focus on the fabrication of microcarriers from droplet microfluidics, and discuss their applications in the biomedical field. We start with the basic principle of droplet microfluidics, including droplet generation regimes and its control methods. We then introduce the fabrication of biomedical microcarriers based on single, double, and multiple emulsion droplets, and emphasize the various applications of microcarriers in biomedical field, especially in 3D cell culture, drug development and biomedical detection. Finally, we conclude this review by discussing the limitations and challenges of droplet microfluidics in preparing microcarriers. STATEMENT OF SIGNIFICANCE: Because of its precise control and high throughput, droplet microfluidics has been employed to generate functional microcarriers, which have been widely used in the areas of drug development, tissue engineering, and regenerative medicine. This review is significant because it emphasizes recent progress in research on droplet microfluidics in the preparation and application of biomedical microcarriers. In addition, this review suggests research directions for the future development of biomedical microcarriers based on droplet microfluidics by presenting existing shortcomings and challenges.

Use of droplet-based microfluidic techniques in the preparation of microparticles

Microparticles are widely used in myriad fields such as pharmaceuticals, foods, cosmetics, and other industrial fields. Compared with traditional methods for synthesizing microparticles, microfluidic techniques provide very powerful platforms for creating highly controllable emulsion droplets as templates for fabricating uniform microparticles with advanced structures and functions. Microfluidic techniques can generate emulsion droplets with precisely controlled size, shape, and composition. A more precise preparation process brings an effective tool to control the release profile of the drug and introduces an easily accessible reproducibility. The paper gives information about basic droplet-based set-ups and examples of attainable microparticle types preparable by this method.

Microfluidics for core-shell drug carrier particles - a review

Core-shell drug-carrier particles are known for their unique features. Due to the combination of superior properties not exhibited by the individual components, core-shell particles have gained a lot of interest. The structures could integrate core and shell characteristics and properties. These particles were designed for controlled drug release in the desired location. Therefore, the side effects would be minimized. So, these particles' advantages have led to the introduction of new methods and ideas for their fabrication. In the past few years, the generation of drug carrier core-shell particles in microfluidic chips has attracted much attention. This method makes it possible to produce particles at nanometer and micrometer levels of the same shape and size; it usually costs less than other methods. The other advantages of using microfluidic techniques compared to conventional bulk methods are integration capability, reproducibility, and higher efficiency. These advantages have created a positive outlook on this approach. This review gives an overview of the various fluidic concepts that are used to generate microparticles or nanoparticles. Also, an overview of traditional and more recent microfluidic devices and their design and structure for the generation of core-shell particles is given. The unique benefits of the microfluidic technique for core-shell drug carrier particle generation are demonstrated.

Sealing 3D-printed parts to poly(dimethylsiloxane) for simple fabrication of Microfluidic devices

Microfluidics has revolutionized the fields of bioanalytical chemistry, cellular biology, and molecular biology. Advancements in microfluidic technologies, however, are often limited by labor, time, and resource-intensive fabrication methods, most commonly a form of photolithography. The advent of 3D printing has helped researchers fabricate proof-of-concept microfluidics more rapidly and at lower costs but suffers from poor resolution and tedious post-processing to remove uncured resin from enclosed channels. Additionally, custom resins and printers are often needed to create entirely enclosed channels, which increases cost and complexity of fabrication. In this work we demonstrate the ability to create microfluidic devices by covalently sealing 3D-printed parts with open-faced channels to polydimethylsiloxane (PDMS). Open-faced channels are easier to print than fully enclosed channels and can be printed using an inexpensive and commercially available stereolithography 3D printer and resin. The 3D-printed parts are sealed to PDMS, a common substrate used in traditional microfluidic fabrication, using two different techniques. The first involves coating the part with a commercially available silicone spray before sealing to PDMS via plasma treatment. In the second technique, the cured methacrylate resin is silanized with (3-Aminopropyl)triethoxysilane (APTES) before binding to PDMS with plasma treatment. Both methods create a strong seal between the two substrates, which is demonstrated with several types of microfluidic devices including droplet and gradient generators.

Multiphase Microfluidics: Fundamentals, Fabrication, and Functions

Multiphase microfluidics enables an alternative approach with many possibilities in studying, analyzing, and manufacturing functional materials due to its numerous benefits over macroscale methods, such as its ultimate controllability, stability, heat and mass transfer capacity, etc. In addition to its immense potential in biomedical applications, multiphase microfluidics also offers new opportunities in various industrial practices including extraction, catalysis loading, and fabrication of ultralight materials. Herein, aiming to give preliminary guidance for researchers from different backgrounds, a comprehensive overview of the formation mechanism, fabrication methods, and emerging applications of multiphase microfluidics using different systems is provided. Finally, major challenges facing the field are illustrated while discussing potential prospects for future work.

Core–shell particles for drug-delivery, bioimaging, sensing, and tissue engineering

Core–shell particles offer significant advantages in their use for bioimaging and biosensors.

High-Throughput Production of Micrometer Sized Double Emulsions and Microgel Capsules in Parallelized 3D Printed Microfluidic Devices

Double emulsions are useful geometries as templates for core-shell particles, hollow sphere capsules, and for the production of biomedical delivery vehicles. In microfluidics, two approaches are currently being pursued for the preparation of microfluidic double emulsion devices. The first approach utilizes soft lithography, where many identical double-flow-focusing channel geometries are produced in a hydrophobic silicone matrix. This technique requires selective surface modification of the respective channel sections to facilitate alternating wetting conditions of the channel walls to obtain monodisperse double emulsion droplets. The second technique relies on tapered glass capillaries, which are coaxially aligned, so that double emulsions are produced after flow focusing of two co-flowing streams. This technique does not require surface modification of the capillaries, as only the continuous phase is in contact with the emulsifying orifice; however, these devices cannot be fabricated in a reproducible manner, which results in polydisperse double emulsion droplets, if these capillary devices were to be parallelized. Here, we present 3D printing as a means to generate four identical and parallelized capillary device architectures, which produce monodisperse double emulsions with droplet diameters in the range of 500 µm. We demonstrate high throughput synthesis of W/O/W and O/W/O double emulsions, without the need for time-consuming surface treatment of the 3D printed microfluidic device architecture. Finally, we show that we can apply this device platform to generate hollow sphere microgels.

Conducting Polymeric Nanocomposites with a Three-Dimensional Co-flow Microfluidics Platform

The nanoprecipitation of polymers is of great interest in biological and medicinal applications. Many approaches are available, but few generalized methods can fabricate structurally different biocompatible polymers into nanosized particles with a narrow distribution in a high-throughput manner. We simply integrate a glass slide, capillary, and metal needle into a simple microfluidics device. Herein, a detailed protocol is provided for using the glass capillary and slides to fabricate the microfluidics devices used in this work. To demonstrate the generality of our nanoprecipitation approach and platform, four (semi)natural polymers—acetalated dextran (Ac-DEX), spermine acetalated dextran (Sp-Ac-DEX), poly(lactic-co-glycolic acid) (PLGA), and chitosan—were tested and benchmarked by the polymeric particle size and polydispersity. More importantly, the principal objective was to explore the influence of some key parameters on nanoparticle size due to its importance for a variety of applications. The polymer concentration, the solvent/non-solvent volume rate/ratio, and opening of the inner capillary were varied so as to obtain polymeric nanoparticles (NPs). Dynamic light scattering (DLS), transmission electron microscopy (TEM), and optical microscopy are the main techniques used to evaluate the nanoprecipitation output. It turns out that the concentration of polymer most strongly determines the particle size and distribution, followed by the solvent/non-solvent volume rate/ratio, whereas the opening of the inner capillary shows a minor effect. The obtained NPs were smooth spheres with adjustable particle diameters and polymer-dependent surface potentials, both negative and positive.

Dynamics of deformation and pinch-off of a migrating compound droplet in a tube

A computational fluid dynamic investigation has been carried out to study the dynamics of a moving compound droplet inside a tube. The motions associated with such a droplet is uncovered by solving the axisymmetric Navier-Stokes equations in which the spatiotemporal evolution of a pair of twin-deformable interfaces has been tracked employing the volume-of-fluid approach. The deformations at the interfaces and their subsequent dynamics are found to be stimulated by the subtle interplay between the capillary and viscous forces. The simulations uncover that when a compound drop composed of concentric inner and outer interfaces migrates inside a tube, initially in the unsteady domain of evolution, the inner drop shifts away from the concentric position to reach a morphology of constant eccentricity at the steady state. The coupled motions of the droplets in the unsteady regime causes a continuous deformation of the inner and outer interfaces to obtain a configuration with a (an) prolate (oblate) shaped outer (inner) interface. The magnitudes of capillary number and viscosity ratio are found to have significant influence on the temporal evolution of the interfacial deformations as well as the eccentricity of the droplets. Further, the simulations uncover that, following the asymmetric deformation of the interfaces, the migrating compound droplet can undergo an uncommon breakup stimulated by a rather irregular pinch-off of the outer shell. The breakup is found to initiate with the thinning of the outer shell followed by the pinch-off. Interestingly, the kinetics of the thinning of outer shell is found to follow two distinct power-law regimes-a swiftly thinning stage at the onset followed by a rate limiting stage before pinch-off, which eventually leads to the uncommon breakup of the migrating compound droplets.

Microfluidic Devices for Drug Delivery Systems and Drug Screening

Microfluidic devices present unique advantages for the development of efficient drug carrier particles, cell-free protein synthesis systems, and rapid techniques for direct drug screening. Compared to bulk methods, by efficiently controlling the geometries of the fabricated chip and the flow rates of multiphase fluids, microfluidic technology enables the generation of highly stable, uniform, monodispersed particles with higher encapsulation efficiency. Since the existing preclinical models are inefficient drug screens for predicting clinical outcomes, microfluidic platforms might offer a more rapid and cost-effective alternative. Compared to 2D cell culture systems and in vivo animal models, microfluidic 3D platforms mimic the in vivo cell systems in a simple, inexpensive manner, which allows high throughput and multiplexed drug screening at the cell, organ, and whole-body levels. In this review, the generation of appropriate drug or gene carriers including different particle types using different configurations of microfluidic devices is highlighted. Additionally, this paper discusses the emergence of fabricated microfluidic cell-free protein synthesis systems for potential use at point of care as well as cell-, organ-, and human-on-a-chip models as smart, sensitive, and reproducible platforms, allowing the investigation of the effects of drugs under conditions imitating the biological system.

Pulsation of electrified jet in capillary microfluidics

In this work, we investigate the pulsation of an electrically charged jet surrounded by an immiscible dielectric liquid in flow-focusing capillary microfluidics. We have characterized a low-frequency large-amplitude pulsation and a high-frequency small-amplitude pulsation, respectively. The former, due to the unbalanced charge and fluid transportation is responsible for generating droplets with a broad size distribution. The latter is intrinsic and produces droplets with a relatively narrow size distribution. Moreover, the average size of the final droplets can be tuned via the intrinsic pulsating frequency through changing the diameter of the emitted liquid jet. Our results provide degree of control over the emulsion droplets with submicron sizes generated in microfluidic-electrospray platform.

Poly(methyl methacrylate) Surface Modification for Surfactant-Free Real-Time Toxicity Assay on Droplet Microfluidic Platform

Microfluidic droplet reactors have many potential uses, from analytical to synthesis. Stable operation requires preferential wetting of the channel surface by the continuous phase which is often not fulfilled by materials commonly used for lab-on-chip devices. Here we show that a silica nanoparticle (SiNP) layer coated onto a Poly(methyl methacrylate) (PMMA) and other thermoplastics surface enhances its wetting properties by creating nanoroughness, and allows simple grafting of hydrocarbon chains through silane chemistry. Using the unusual stability of silica sols at their isoelectric point, a dense SiNP layer is adsorbed onto PMMA and renders the surface superhydrophilic. Subsequently, a self-assembled dodecyltrichlorosilane (DTS) monolayer yields a superhydrophobic surface that allows the repeatable generation of aqueous droplets in a hexadecane continuous phase without surfactant addition. A SiNP-DTS modified chip has been used to monitor bacterial viability with a resazurin assay. The whole process involving sequential reagents injection, and multiplexed droplet fluorescence intensity monitoring is carried out on chip. Metabolic inhibition of the anaerobe Enterococcus faecalis by 30 mg L^-1 of NiCl₂ was detected in 5 min.

Marker patterning: a spatially resolved method for tuning the wettability of PDMS

This article presents a marker patterning method where a permanent ink is used as a masking layer. During plasma oxidation, the PDMS surfaces are protected leading to a simple and easy wettability patterning.

Mass-Transfer-Controlled Dynamic Interfacial Tension in Microfluidic Emulsification Processes

Varied interfacial tension caused by the unsaturated adsorption of surfactants on dripping droplet surfaces is experimentally studied. The mass transfer and adsorption of surfactants, as well as the generation of fresh interfaces, are considered the main factors dominating the surfactant adsorption ratio on droplet surfaces. The diffusion and convective mass transfer of the surfactants are first distinguished by comparing the adsorption depth and the mass flux boundary layer thickness. A characterized mass transfer time is then calculated by introducing an effective diffusion coefficient. A time ratio is furthermore defined by dividing the droplet generation time by the characteristic mass transfer time, t/tm, in order to compare the rates of surfactant mass transfer and droplet generation. Different control mechanisms for different surfactants are analyzed based on the range of t/t(m), and a criterion time ratio using a simplified characteristic mass transfer time, t(m)*, is finally proposed for predicting the appearance of dynamic interfacial tension.

Continuous generation of alginate microfibers with spindle-knots by using a simple microfluidic device

Calcium alginate microfibers with spindle-knots are fabricated by combining microfluidic technique with wet-spinning method. The structures of the knots can be conveniently regulated by changing the two-phase flow rate ratio and the micropipette diameter.

Automated formation of multicomponent-encapuslating vesosomes using continuous flow microcentrifugation

Vesosomes - hierarchical assemblies consisting of membrane-bound vesicles of various scales - are potentially powerful models of cellular compartmentalization. Current methods of vesosome fabrication are labor intensive, and offer little control over the size and uniformity of the final product. In this article, we report the development of an automated vesosome formation platform using a microfluidic device and a continuous flow microcentrifuge. In the microfluidic device, water-in-oil droplets containing nanoscale vesicles in the water phase were formed using T-junction geometry, in which a lipid monolayer is formed at the oil/water interface. These water-in-oil droplets were then immediately transferred to the continuous flow microcentrifuge. When a water-in-oil droplet passed through a second lipid monolayer formed in the continuous flow microcentrifuge, a bilayer-encapsulated vesosome was created, which contained all of the contents of the aqueous phase encapsulated within the vesosome. Encapsulation of nanoscale liposomes within the outer vesosome membrane was confirmed by fluorescence microscopy. Laser diffraction analysis showed that the vesosomes we fabricated were uniform (coefficient of variation of 0.029). The yield of the continuous flow microcentrifuge is high, with over 60% of impinging water droplets being converted to vesosomes. Our system provides a fully automatable route for the generation of vesosomes encapsulating arbitrary contents. The method employed in this work is simple and can be readily applied to a variety of systems, providing a facile platform for fabricating multicomponent carriers and model cells.

Syringe-pump-induced fluctuation in all-aqueous microfluidic system implications for flow rate accuracy

We report a new method to display the minute fluctuations induced by syringe pumps on microfluidic flows by using a liquid-liquid system with an ultralow interfacial tension. We demonstrate that the stepper motor inside the pump is a source of fluctuations in microfluidic flows by comparing the frequencies of the ripples observed at the interface to that of the pulsation of the stepper motor. We also quantify the fluctuations induced at different flow rates, using syringes of different diameters, and using different syringe pumps with different advancing distances per step. Our work provides a way to predict the frequency of the fluctuation that the driving syringe pump induces on a microfluidic system and suggests that syringe pumps can be a source of fluctuations in microfluidic flows, thus contributing to the polydispersity of the resulting droplets.