Co-axial capillaries microfluidic device for synthesizing size- and morphology-controlled polymer core-polymer shell particles

Droplet Microfluidics for Current Cancer Research: From Single-Cell Analysis to 3D Cell Culture

Cancer is the second leading cause of death worldwide. Differences in drug resistance and treatment response caused by the heterogeneity of cancer cells are the primary reasons for poor cancer therapy outcomes in patients. In addition, current in vitro anticancer drug-screening methods rely on two-dimensional monolayer-cultured cancer cells, which cannot accurately predict drug behavior in vivo. Therefore, a powerful tool to study the heterogeneity of cancer cells and produce effective in vitro tumor models is warranted to leverage cancer research. Droplet microfluidics has become a powerful platform for the single-cell analysis of cancer cells and three-dimensional cell culture of in vitro tumor spheroids. In this review, we discuss the use of droplet microfluidics in cancer research. Droplet microfluidic technologies, including single- or double-emulsion droplet generation and passive- or active-droplet manipulation, are concisely discussed. Recent advances in droplet microfluidics for single-cell analysis of cancer cells, circulating tumor cells, and scaffold-free/based 3D cell culture of tumor spheroids have been systematically introduced. Finally, the challenges that must be overcome for the further application of droplet microfluidics in cancer research are discussed.

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

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

Dynamic Behaviours of Monodisperse Double Emulsion Formation in a Tri-Axial Capillary Device

We investigated experimentally, analytically, and numerically the formation process of double emulsion formations under a dripping regime in a tri-axial co-flow capillary device. The results show that mismatches of core and shell droplets under a given flow condition can be captured both experimentally and numerically. We propose a semi-analytical model using the match ratio between the pinch-off length of the shell droplet and the product of the core growth rate and its pinch-off time. The mismatch issue can be avoided if the match ratio is lower than unity. We considered a model with the wall effect to predict the size of the matched double emulsion. The model shows slight deviations with experimental data if the Reynolds number of the continuous phase is lower than 0.06 but asymptotically approaches good agreement if the Reynolds number increases from 0.06 to 0.14. The numerical simulation generally agrees with the experiments under various flow conditions.

Systematic characterization of effect of flow rates and buffer compositions on double emulsion droplet volumes and stability

Double emulsion droplets (DEs) are water/oil/water droplets that can be sorted via fluorescence-activated cell sorting (FACS), allowing for new opportunities in high-throughput cellular analysis, enzymatic screening, and synthetic biology. These applications require stable, uniform droplets with predictable microreactor volumes. However, predicting DE droplet size, shell thickness, and stability as a function of flow rate has remained challenging for monodisperse single core droplets and those containing biologically-relevant buffers, which influence bulk and interfacial properties. As a result, developing novel DE-based bioassays has typically required extensive initial optimization of flow rates to find conditions that produce stable droplets of the desired size and shell thickness. To address this challenge, we conducted systematic size parameterization quantifying how differences in flow rates and buffer properties (viscosity and interfacial tension at water/oil interfaces) alter droplet size and stability, across 6 inner aqueous buffers used across applications such as cellular lysis, microbial growth, and drug delivery, quantifying the size and shell thickness of >22 000 droplets overall. We restricted our study to stable single core droplets generated in a 2-step dripping-dripping formation regime in a straightforward PDMS device. Using data from 138 unique conditions (flow rates and buffer composition), we also demonstrated that a recent physically-derived size law of Wang et al. can accurately predict double emulsion shell thickness for >95% of observations. Finally, we validated the utility of this size law by using it to accurately predict droplet sizes for a novel bioassay that requires encapsulating growth media for bacteria in droplets. This work has the potential to enable new screening-based biological applications by simplifying novel DE bioassay development.

Trojan pH-Sensitive Polymer Particles Produced in a Continuous-Flow Capillary Microfluidic Device Using Water-in-Oil-in-Water Double-Emulsion Droplets

A facile and robust microfluidic method to produce nanoparticle-in-microparticle systems (Trojan systems) is reported as a delivery vector for the oral administration of active pharmaceutical ingredients. The microfluidic system is based on two coaxial capillaries that produce monodisperse water-in-oil-in-water (W/O/W) double emulsions in a highly controlled fashion with precise control over the resulting particle structure, including the core and shell dimensions. The influence of the three phase flow rates, pH and drying process on the formation and overall size is evaluated. These droplets are then used as templates for the production of pH-sensitive Trojan microparticles after solvent evaporation. The shell of Trojan microparticles is made of Eudragit^®, a methacrylic acid-ethyl acrylate copolymer that would enable the Trojan microparticle payload to first pass through the stomach without being degraded and then dissolve in the intestinal fluid, releasing the inner payload. The synthesis of the pH-sensitive Trojan microparticles was also compared with a conventional batch production method. The payloads considered in this work were different in nature: (1) fluorescein, to validate the feasibility of the polymeric shell to protect the payload under gastric pH; (2) poly(D,L-lactic acid/glycolic acid)-PLGA nanoparticles loaded with the antibiotic rifampicin. These PLGA nanoparticles were produced also using a microfluidic continuous process and (3) PLGA nanoparticles loaded with Au nanoparticles to trace the PLGA formulation under different environments (gastric and intestinal), and to assess whether active pharmaceutical ingredient (API) encapsulation in PLGA is due efficiently. We further showed that Trojan microparticles released the embedded PLGA nanoparticles in contact with suitable media, as confirmed by electron microscopy. Finally, the results show the possibility of developing Trojan microparticles in a continuous manner with the ability to deliver therapeutic nanoparticles in the gastrointestinal tract.

Microfluidic synthesis of optically responsive materials for nano- and biophotonics

Recently, nanomaterials demonstrating optical response under illumination, the so-called optically responsive nanoparticles (NPs), have found their broad application as optical switchers, gas adsorbents, data storage devices, and optical and biological sensors. Unique optical properties of such nanomaterials are strongly related to their chemical composition, geometrical parameters and morphology. Microfluidic approaches for NPs' synthesis allow overcoming the known critical stages in conventional synthesis of NPs due to a high rate of heat/mass transfer and precise regulation of synthesis conditions, which results in reproducible synthesis outcomes with the desired physico-chemical properties. Here, we review the recent advances in microfluidic approach for synthesis of optically responsive nanomaterials (plasmonic, photoluminescent, shape-changeable NPs), highlighting the general background of microfluidics, common considerations in the design of microfluidic chips (MFCs), and theoretical models of the NPs' formation mechanisms. Comparative analysis of microfluidic synthesis with conventional synthesis methods is provided further, along with the recent applications of optically responsive NPs in nano- and biophotonics.

Microfluidic encapsulation for controlled release and its potential for nanofertilisers

Nanotechnology is increasingly being utilized to create advanced materials with improved or new functional attributes. Converting fertilizers into a nanoparticle-form has been shown to improve their efficacy but the current procedures used to fabricate nanofertilisers often have poor reproducibility and flexibility. Microfluidic systems, on the other hand, have advantages over traditional nanoparticle fabrication methods in terms of energy and materials consumption, versatility, and controllability. The increased controllability can result in the formation of nanoparticles with precise and complex morphologies (e.g., tuneable sizes, low polydispersity, and multi-core structures). As a result, their functional performance can be tailored to specific applications. This paper reviews the principles, formation, and applications of nano-enabled delivery systems fabricated using microfluidic approaches for the encapsulation, protection, and release of fertilizers. Controlled release can be achieved using two main routes: (i) nutrients adsorbed on nanosupports and (ii) nutrients encapsulated inside nanostructures. We aim to highlight the opportunities for preparing a new generation of highly versatile nanofertilisers using microfluidic systems. We will explore several main characteristics of microfluidically prepared nanofertilisers, including droplet formation, shell fine-tuning, adsorbate fine-tuning, and sustained/triggered release behavior.

Core–Shell Droplet Generation Device Using a Flexural Bolt-Clamped Langevin-Type Ultrasonic Transducer

Droplets with a core–shell structure formed from two immiscible liquids are used in various industrial field owing to their useful physical and chemical characteristics. Efficient generation of uniform core–shell droplets plays an important role in terms of productivity. In this study, monodisperse core-shell droplets were efficiently generated using a flexural bolt-clamped Langevin-type transducer and two micropore plates. Water and silicone oil were used as core and shell phases, respectively, to form core–shell droplets in air. When the applied pressure of the core phase, the applied pressure of the shell phase, and the vibration velocity in the micropore were 200 kPa, 150 kPa, and 8.2 mm/s, respectively, the average diameter and coefficient of variation of the droplets were 207.7 μm and 1.6%, respectively. A production rate of 29,000 core–shell droplets per second was achieved. This result shows that the developed device is effective for generating monodisperse core–shell droplets.

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.

Core-shell nanoparticles used in drug delivery-microfluidics: a review

Developments in the fields of lab-on-a-chip and microfluidic technology have benefited nanomaterial production processes due to fluid miniaturization. The ability to acquire, manage, create, and modify structures on a nanoscale is of great interest in scientific and technological fields. Recently, more attention has been paid to the production of core-shell nanomaterials because of their use in various fields, such as drug delivery. Heterostructured nanomaterials have more reliable performance than the individual core or shell materials. Nanoparticle synthesis is a complex process; therefore, various techniques exist for the production of different types of nanoparticles. Among these techniques, microfluidic methods are unique and reliable routes, which can be used to produce nanoparticles for drug delivery applications.

Preparation and Deep Characterization of Composite/Hybrid Multi-Scale and Multi-Domain Polymeric Microparticles

Polymeric microparticles were produced following a three-step procedure involving (i) the production of an aqueous nanoemulsion of tri and monofunctional acrylate-based monomers droplets by an elongational-flow microemulsifier, (ii) the production of a nanosuspension upon the continuous-flow UV-initiated miniemulsion polymerization of the above nanoemulsion and (iii) the production of core-shell polymeric microparticles by means of a microfluidic capillaries-based double droplets generator; the core phase was composed of the above nanosuspension admixed with a water-soluble monomer and gold salt, the shell phase comprised a trifunctional monomer, diethylene glycol and a silver salt; both phases were photopolymerized on-the-fly upon droplet formation. Resulting microparticles were extensively analyzed by energy dispersive X-rays spectrometry and scanning electron microscopy to reveal the core-shell morphology, the presence of silver nanoparticles in the shell, organic nanoparticles in the core but failed to reveal the presence of the gold nanoparticles in the core presumably due to their too small size (c.a. 2.5 nm). Nevertheless, the reddish appearance of the as such prepared polymer microparticles emphasized that this three-step procedure allowed the easy elaboration of composite/hybrid multi-scale and multi-domain polymeric microparticles.

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.

Microfluidic-assisted preparation of PLGA nanoparticles for drug delivery purposes: experimental study and computational fluid dynamic simulation

This study, for the first time, tries to provide a simultaneous experimental and computational fluid dynamic (CFD) simulation investigation for production of uniform, reproducible, and stable polylactic-co-glycolic acid (PLGA) nanoparticles. CFD simulation was carried out to observe fluid flow behavior and micromixing in microfluidic system and improve our understanding about the governing fluid profile. The major objective of such effort was to provide a carrier for controlled and sustained release profile of different drugs. Different experimental parameters were optimized to obtain PLGA nanoparticles with proper size and minimized polydispersity index. The particle size, polydispersity, morphology, and stability of nanoparticles were compared. Microfluidic system provided a platform to control over the characteristics of nanoparticles. Using microfluidic system, the obtained particles were more uniform and harmonious in size, more stable, monodisperse and spherical, while particles produced by batch method were non-spherical and polydisperse. The best size and polydispersity index in the microfluidic method was obtained using 2% PLGA and 0.0625% (w/v) polyvinyl alcohol (PVA) solutions, and the flow rate ratio of 10:0.6 for PVA and PLGA solutions. CFD simulation demonstrated the high mixing intensity of about 0.99 at optimum condition in the microfluidic system, which is the possible reason for advantageous performance of this system. Altogether, the results of microfluidic-assisted method were found to be more reproducible, predictable, and controllable than batch method for producing a nanoformulation for delivery of drugs.

Current status and future developments in preparation and application of nonspherical polymer particles

Nonspherical polymer particles (NPPs) are nano/micro-particulates of macromolecules that are anisotropic in shape, and can be designed anisotropic in chemistry. Due to shape and surface anisotropies, NPPs bear many unique structures and fascinating properties which are distinctly different from those of spherical polymer particles (SPPs). In recent years, the research on NPPs has surprisingly blossomed in recent years, and many practical materials based on NPPs with potential applications in photonic device, material science and biomedical engineering have been generated. In this review, we give a systematic, balanced and comprehensive summary of the main aspects of NPPs related to their preparation and application, and propose perspectives for the future developments of NPPs.

Microfluidic Preparation of Liquid Crystalline Elastomer Actuators

This paper focuses on the microfluidic process (and its parameters) to prepare actuating particles from liquid crystalline elastomers. The preparation usually consists in the formation of droplets containing low molar mass liquid crystals at elevated temperatures. Subsequently, these particle precursors are oriented in the flow field of the capillary and solidified by a crosslinking polymerization, which produces the final actuating particles. The optimization of the process is necessary to obtain the actuating particles and the proper variation of the process parameters (temperature and flow rate) and allows variations of size and shape (from oblate to strongly prolate morphologies) as well as the magnitude of actuation. In addition, it is possible to vary the type of actuation from elongation to contraction depending on the director profile induced to the droplets during the flow in the capillary, which again depends on the microfluidic process and its parameters. Furthermore, particles of more complex shapes, like core-shell structures or Janus particles, can be prepared by adjusting the setup. By the variation of the chemical structure and the mode of crosslinking (solidification) of the liquid crystalline elastomer, it is also possible to prepare actuating particles triggered by heat or UV-vis irradiation.

Droplet Microfluidics for the Production of Microparticles and Nanoparticles

Droplet microfluidics technology is recently a highly interesting platform in material fabrication. Droplets can precisely monitor and control entire material fabrication processes and are superior to conventional bulk techniques. Droplet production is controlled by regulating the channel geometry and flow rates of each fluid. The micro-scale size of droplets results in rapid heat and mass-transfer rates. When used as templates, droplets can be used to develop reproducible and scalable microparticles with tailored sizes, shapes and morphologies, which are difficult to obtain using traditional bulk methods. This technology can revolutionize material processing and application platforms. Generally, microparticle preparation methods involve three steps: (1) the formation of micro-droplets using a microfluidics generator; (2) shaping the droplets in micro-channels; and (3) solidifying the droplets to form microparticles. This review discusses the production of microparticles produced by droplet microfluidics according to their morphological categories, which generally determine their physicochemical properties and applications.

Macroporous materials: microfluidic fabrication, functionalization and applications

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.

Semipermeable Elastic Microcapsules for Gas Capture and Sensing

Monodispersed microcapsules for gas capture and sensing were developed consisting of elastic semipermeable polymer shells of tunable size and thickness and pH-sensitive, gas selective liquid cores. The microcapsules were produced using glass capillary microfluidics and continuous on-the-fly photopolymerization. The inner fluid was 5-30 wt % K2CO3 solution with m-cresol purple, the middle fluid was a UV-curable liquid silicon rubber containing 0-2 wt % Dow Corning 749 fluid, and the outer fluid was aqueous solution containing 60-70 wt % glycerol and 0.5-2 wt % stabilizer (poly(vinyl alcohol), Tween 20, or Pluronic F-127). An analytical model was developed and validated for prediction of the morphology of the capsules under osmotic stress based on the shell properties and the osmolarity of the storage and core solutions. The minimum energy density and UV light irradiance needed to achieve complete shell polymerization were 2 J·cm(-2) and 13.8 mW·cm(-2), respectively. After UV exposure, the curing time for capsules containing 0.5 wt % Dow Corning 749 fluid in the middle phase was 30-40 min. The CO2 capture capacity of 30 wt % K2CO3 capsules was 1.6-2 mmol/g depending on the capsule size and shell thickness. A cavitation bubble was observed in the core when the internal water was abruptly removed by capillary suction, whereas a gradual evaporation of internal water led to buckling of the shell. The shell was characterized using TGA, DSC, and FTIR. The shell degradation temperature was 450-460 °C.

Composite Sensor Particles for Tuned SERS Sensing: Microfluidic Synthesis, Properties and Applications

Surface-enhanced Raman scattering (SERS) is a promising platform for particle-based sensor signaling, and droplet-based microfluidic systems are particularly advantageous for control of the size and composition of micro- and nanoparticles. For controlled sensing application, a high homogeneity of the sensor particles is a key requirement, and the particles with functional properties demand for the preparation in a minimum number of synthesis steps. Frequently used coflow and flow focusing arrangements, however, produce the microparticles of only larger size. To address such concern for downscaling of particle size, which is crucial for strong sensing outcome, we have used a peculiar micro cross-flow arrangement here for generating the polymer microparticles of broad size range between 30 and 600 μm along with in situ embedded silver nanoparticles. Embedded silver acts as nuclei for additional silver enforcement via silver-catalyzed silver deposition in order to realize the composite microparticles for SERS sensing. The homogeneous size and spatial distribution of silver nanoparticles inside the matrix and enforcement over the surface together with controlled pore size provides a high and homogeneous loading of polymer composite sensor. Moreover, different parameters such as analytes concentration and particles size have been studied here for SERS sensing application of biochemical molecules (amino acids and vitamins). Overall, the platform for size-tuned droplets generation, synthesis of composite microparticles, mechanism for synchronized photopolymerization-photoreduction, tuned silver enforcement, and the impacts of different analytes on differently composed microparticles are systematically investigated in this paper.

Dynamics of double emulsion break-up in three phase glass capillary microfluidic devices

Pinch-off of a compound jet in 3D glass capillary microfluidic device, which combines co-flowing and countercurrent flow focusing geometries, was investigated using an incompressible three-phase axisymmetric Volume of Fluid-Continuum Surface Force (VOF-CSF) numerical model. The model showed good agreement with the experimental drop generation and was capable of predicting formation of core/shell droplets in dripping, narrowing jetting and widening jetting regimes. In dripping and widening jetting regimes, the presence of a vortex flow around the upstream end of the necking thread facilitates the jet break-up. No vortex flow was observed in narrowing jetting regime and pinch-off occurred due to higher velocity at the downstream end of the coaxial thread compared to that at the upstream end. In all regimes, the inner jet ruptured before the outer jet, preventing a leakage of the inner drop into the outer fluid. The necking region moves at the maximum speed in the narrowing jetting regime, due to the highest level of shear at the outer surface of the thread. However, in widening jetting regime, the neck travels the longest distance downstream before it breaks.

Large ultrathin shelled drops produced via non-confined microfluidics

We present a facile approach for producing large and monodisperse core-shell drops with ultrathin shells using a single-step process. A biphasic compound jet is introduced into a quiescent third (outer) phase that ruptures to form core-shell drops. Ultrathin shelled drops could only be produced within a certain range of surfactant concentrations and flow rates, highlighting the effect of interfacial tension in engulfing the core in a thin shell. An increase in surfactant concentrations initially resulted in drops with thinner shells. However, the drops with thinnest shells were obtained at an optimum surfactant concentration, and a further increase in the surfactant concentrations increased the shell thickness. Highly monodisperse (coefficient of variation smaller than 3 %) core-shell drops with diameter of ∼200 μm-2 mm with shell thickness as small as ∼2 μm were produced. The resulting drops were stable enough to undergo polymerisation and produce ultrathin shelled capsules.

An "off-the-shelf" capillary microfluidic device that enables tuning of the droplet breakup regime at constant flow rates

The fabrication of glass capillary microfluidic devices is technically challenging, often hampering use of the design. We describe a new technique, based on commercially available components, for assembling flow focusing capillary devices that can readily be taken apart and cleaned between uses. This design strategy allows for generation of both water-in-oil and oil-in-water emulsions in the same device after an ethanol rinse. The modularity of the device enables the adjustment of the tip separation between the two inner capillaries during droplet generation, which enables tuning of the age of the interface. Time-dependent surfactant diffusion to the interface changes the interfacial tension, thus providing an approach for adjusting the capillary number in addition to the usual method of changing flow rates. This design enables the tuning of the mode of breakup and the droplet size.

Multiphase flow microfluidics for the production of single or multiple emulsions for drug delivery

Considerable effort has been directed towards developing novel drug delivery systems. Microfluidics, capable of generating monodisperse single and multiple emulsion droplets, executing precise control and operations on these droplets, is a powerful tool for fabricating complex systems (microparticles, microcapsules, microgels) with uniform size, narrow size distribution and desired properties, which have great potential in drug delivery applications. This review presents an overview of the state-of-the-art multiphase flow microfluidics for the production of single emulsions or multiple emulsions for drug delivery. The review starts with a brief introduction of the approaches for making single and multiple emulsions, followed by presentation of some potential drug delivery systems (microparticles, microcapsules and microgels) fabricated in microfluidic devices using single or multiple emulsions as templates. The design principles, manufacturing processes and properties of these drug delivery systems are also discussed and compared. Furthermore, drug encapsulation and drug release (including passive and active controlled release) are provided and compared highlighting some key findings and insights. Finally, site-targeting delivery using multiphase flow microfluidics is also briefly introduced.