A stable droplet reactor for high temperature nanocrystal synthesis

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.

Microfluidic synthesis of nanomaterials for biomedical applications

The field of nanomaterials has progressed dramatically over the past decades with important contributions to the biomedical area. The physicochemical properties of nanomaterials, such as the size and structure, can be controlled through manipulation of mass and heat transfer conditions during synthesis. In particular, microfluidic systems with rapid mixing and precise fluid control are ideal platforms for creating appropriate synthesis conditions. One notable example of microfluidics-based synthesis is the development of lipid nanoparticle (LNP)-based mRNA vaccines with accelerated clinical translation and robust efficacy during the COVID-19 pandemic. In addition to LNPs, microfluidic systems have been adopted for the controlled synthesis of a broad range of nanomaterials. In this review, we introduce the fundamental principles of microfluidic technologies including flow field- and multiple field-based methods for fabricating nanoparticles, and discuss their applications in the biomedical field. We conclude this review by outlining several major challenges and future directions in the implementation of microfluidic synthesis of nanomaterials.

Microfluidic Devices: A Tool for Nanoparticle Synthesis and Performance Evaluation

The use of nanoparticles (NPs) in nanomedicine holds great promise for the treatment of diseases for which conventional therapies present serious limitations. Additionally, NPs can drastically improve early diagnosis and follow-up of many disorders. However, to harness their full capabilities, they must be precisely designed, produced, and tested in relevant models. Microfluidic systems can simulate dynamic fluid flows, gradients, specific microenvironments, and multiorgan complexes, providing an efficient and cost-effective approach for both NPs synthesis and screening. Microfluidic technologies allow for the synthesis of NPs under controlled conditions, enhancing batch-to-batch reproducibility. Moreover, due to the versatility of microfluidic devices, it is possible to generate and customize endless platforms for rapid and efficient in vitro and in vivo screening of NPs' performance. Indeed, microfluidic devices show great potential as advanced systems for small organism manipulation and immobilization. In this review, first we summarize the major microfluidic platforms that allow for controlled NPs synthesis. Next, we will discuss the most innovative microfluidic platforms that enable mimicking in vitro environments as well as give insights into organism-on-a-chip and their promising application for NPs screening. We conclude this review with a critical assessment of the current challenges and possible future directions of microfluidic systems in NPs synthesis and screening to impact the field of nanomedicine.

Microreactor-based micro/nanomaterials: fabrication, advances, and outlook

Micro/nanomaterials are widely used in optoelectronics, environmental materials, bioimaging, agricultural industries, and drug delivery owing to their marvelous features, such as quantum tunneling, size, surface and boundary, and Coulomb blockade effects. Recently, microreactor technology has opened up broad prospects for green and sustainable chemical synthesis as a powerful tool for process intensification and microscale manipulation. This review focuses on recent progress in the microreactor synthesis of micro/nanomaterials. First, the fabrication and design principles of existing microreactors for producing micro/nanomaterials are summarized and classified. Afterwards, typical examples are shown to demonstrate the fabrication of micro/nanomaterials, including metal nanoparticles, inorganic nonmetallic nanoparticles, organic nanoparticles, Janus particles, and MOFs. Finally, the future research prospects and key issues of microreactor-based micro/nanomaterials are discussed. In short, microreactors provide new ideas and methods for the synthesis of micro/nanomaterials, which have huge potential and inestimable possibilities in large-scale production and scientific research.

Non-fouling flow reactors for nanomaterial synthesis

This review provides a holistic description of flow reactor fouling for wet-chemical nanomaterial syntheses. Fouling origins and consequences are discussed together with the variety of flow reactors for its prevention.

A versatile non-fouling multi-step flow reactor platform: demonstration for partial oxidation synthesis of iron oxide nanoparticles

In the last decade flow reactors for material synthesis were firmly established, demonstrating advantageous operating conditions, reproducible and scalable production via continuous operation, as well as high-throughput screening of synthetic conditions. Reactor fouling, however, often restricts flow chemistry and the common fouling prevention via segmented flow comes at the cost of inflexibility. Often, the difficulty of feeding reagents into liquid segments (droplets or slugs) constrains flow syntheses using segmented flow to simple synthetic protocols with a single reagent addition step prior or during segmentation. Hence, the translation of fouling prone syntheses requiring multiple reagent addition steps into flow remains challenging. This work presents a modular flow reactor platform overcoming this bottleneck by fully exploiting the potential of three-phase (gas-liquid-liquid) segmented flow to supply reagents after segmentation, hence facilitating fouling free multi-step flow syntheses. The reactor design and materials selection address the operation challenges inherent to gas-liquid-liquid flow and reagent addition into segments allowing for a wide range of flow rates, flow ratios, temperatures, and use of continuous phases (no perfluorinated solvents needed). This "Lego®-like" reactor platform comprises elements for three-phase segmentation and sequential reagent addition into fluid segments, as well as temperature-controlled residence time modules that offer the flexibility required to translate even complex nanomaterial synthesis protocols to flow. To demonstrate the platform's versatility, we chose a fouling prone multi-step synthesis, i.e., a water-based partial oxidation synthesis of iron oxide nanoparticles. This synthesis required I) the precipitation of ferrous hydroxides, II) the addition of an oxidation agent, III) a temperature treatment to initiate magnetite/maghemite formation, and IV) the addition of citric acid to increase the colloidal stability. The platform facilitated the synthesis of colloidally stable magnetic nanoparticles reproducibly at well-controlled synthetic conditions and prevented fouling using heptane as continuous phase. The biocompatible particles showed excellent heating abilities in alternating magnetic fields (ILP values >3 nH m² kg_Fe^-1), hence, their potential for magnetic hyperthermia cancer treatment. The platform allowed for long term operation, as well as screening of synthetic conditions to tune particle properties. This was demonstrated via the addition of tetraethylenepentamine, confirming its potential to control particle morphology. Such a versatile reactor platform makes it possible to translate even complex syntheses into flow, opening up new opportunities for material synthesis.

Scalable Production of High-Quality Silver Nanowires via Continuous-Flow Droplet Synthesis

Silver nanowires (Ag NWs) have shown great potential in next-generation flexible displays, due to their superior electronic, optical, and mechanical properties. However, as with most nanomaterials, a limited production capacity and poor reproduction quality, based on the batch reaction, largely hinder their application. Here, we applied continuous-flow synthesis for the scalable and high-quality production of Ag NWs, and built a pilot-scale line for kilogram-level per day production. In addition, we found that trace quantities of water could generate sufficient vapor as a spacer under high temperature to efficiently prevent the back-flow or mixed-flow of the reaction solution. With an optimized synthetic formula, a mass production of pure Ag NWs of 36.5 g/h was achieved by a multiple-channel, continuous-flow reactor.

Microfluidic technologies for nanoparticle formation

Functional nanoparticles (NPs) hold immense promise in diverse fields due to their unique biological, chemical, and physical properties associated with size or morphology. Microfluidic technologies featuring precise fluid manipulation have become versatile toolkits for manufacturing NPs in a highly controlled manner with low batch-to-batch variability. In this review, we present the fundamentals of microfluidic fabrication strategies, including mixing-, droplet-, and multiple field-based microfluidic methods. We highlight the formation of functional NPs using these microfluidic reactors, with an emphasis on lipid NPs, polymer NPs, lipid-polymer hybrid NPs, supramolecular NPs, metal and metal-oxide NPs, metal-organic framework NPs, covalent organic framework NPs, quantum dots, perovskite nanocrystals, biomimetic NPs, etc. we discuss future directions in microfluidic fabrication for accelerated development of functional NPs, such as device parallelization for large-scale NP production, highly efficient optimization of NP formulations, and AI-guided design of multi-step microfluidic reactors.

Mild Microfluidic Approaches to Oxide Nanoparticles Synthesis

Oxide nanoparticles (oxide NPs) are advanced materials with a wide variety of applications in different fields. The use of continuous flow methods is particularly appealing for their synthesis due to the high control achieved over the reaction conditions and the easy process scalability. The present review focuses on the preparation of oxide NPs using microfluidic setups at low temperature (≤80 °C), since the employment of mild reaction conditions is crucial for developing sustainable and cost-effective processes. A particular emphasis will be put on the improvement over the final product features (e. g., size, shape, and size distribution) given by flow methods with respect to conventional batch procedures. The main issues that arise by treating NPs suspensions in microfluidic systems are product deposition or channel clogging; mitigation strategies to overcome these drawbacks will also be presented and discussed.

Continuous segmented-flow synthesis of Ag and Au nanoparticles using a low-cost microfluidic PTFE tubing reactor

We present in here a simple and low cost continuous segmented-flow process for the synthesis of Ag and Au spherical-shaped nanoparticles. Different residence times (RT) were used to perform the nanoparticle synthesis, observing that at low RT, the Ag nanoparticles production, which uses a fast reduction reaction with NaBH4, is improved due to an enhancement in the mixing of the reactants. However, the flow conditions have an opposite effect in the case of Au nanoparticles synthesis. Indeed, since the chemical reduction process (Turkevich method) exhibit a much slower kinetics, high RT (low flowrates) improve the synthesis yield and the quality of the nanoparticles. The Ag and Au nanoparticles were characterized by UV-Vis spectrophotometry (UV-Vis) and Transmission Electron Microscopy (TEM). The Ag spherical-shaped nanoparticles presented a LSPR at 400 nm (size ≈ 4 nm), while the synthesized Au nanoparticles exhibit LSPR and sizes in the range 520 - 550 nm and 14 - 17 nm, respectively.

Microfluidic formulation of nanoparticles for biomedical applications

Nanomedicine has made significant advances in clinical applications since the late-20th century, in part due to its distinct advantages in biocompatibility, potency, and novel therapeutic applications. Many nanoparticle (NP) therapies have been approved for clinical use, including as imaging agents or as platforms for drug delivery and gene therapy. However, there are remaining challenges that hinder translation, such as non-scalable production methods and the inefficiency of current NP formulations in delivering their cargo to their target. To address challenges with existing formulation methods that have batch-to-batch variability and produce particles with high dispersity, microfluidics-devices that manipulate fluids on a micrometer scale-have demonstrated enormous potential to generate reproducible NP formulations for therapeutic, diagnostic, and preventative applications. Microfluidic-generated NP formulations have been shown to have enhanced properties for biomedical applications by formulating NPs with more controlled physical properties than is possible with bulk techniques-such as size, size distribution, and loading efficiency. In this review, we highlight advances in microfluidic technologies for the formulation of NPs, with an emphasis on lipid-based NPs, polymeric NPs, and inorganic NPs. We provide a summary of microfluidic devices used for NP formulation with their advantages and respective challenges. Additionally, we provide our analysis for future outlooks in the field of NP formulation and microfluidics, with emerging topics of production scale-independent formulations through device parallelization and multi-step reactions within droplets.

Nanocrystal synthesis, μfluidic sample dilution and direct extraction of single emission linewidths in continuous flow

The rational design of semiconductor nanocrystal populations requires control of their emission linewidths, which are dictated by interparticle inhomogeneities and single-nanocrystal spectral linewidths. To date, research efforts have concentrated on minimizing the ensemble emission linewidths, however there is little knowledge about the synthetic parameters dictating single-nanocrystal linewidths. In this direction, we present a flow-based system coupled with an optical interferometry setup for the extraction of single nanocrystal properties. The platform has the ability to synthesize nanocrystals at high temperature <300 °C, adjust the particle concentration after synthesis and extract ensemble-averaged single nanocrystal emission linewidths using flow photon-correlation Fourier spectroscopy.

Influence of Experimental Parameters of a Continuous Flow Process on the Properties of Very Small Iron Oxide Nanoparticles (VSION) Designed for T1-Weighted Magnetic Resonance Imaging (MRI)

This study reports the development of a continuous flow process enabling the synthesis of very small iron oxide nanoparticles (VSION) intended for T₁-weighted magnetic resonance imaging (MRI). The influence of parameters, such as the concentration/nature of surfactants, temperature, pressure and the residence time on the thermal decomposition of iron(III) acetylacetonate in organic media was evaluated. As observed by transmission electron microscopy (TEM), the diameter of the resulting nanoparticle remains constant when modifying the residence time. However, significant differences were observed in the magnetic and relaxometric studies. This continuous flow experimental setup allowed the production of VSION with high flow rates (up to 2 mL·min⁻¹), demonstrating the efficacy of such process compared to conventional batch procedure for the scale-up production of VSION.

Continuous Synthesis of Nanocrystals via Flow Chemistry Technology

Modern nanotechnologies bring humanity to a new age, and advanced methods for preparing functional nanocrystals are cornerstones. A considerable variety of nanomaterials has been created over the past decades, but few were prepared on the macro scale, even fewer making it to the stage of industrial production. The gap between academic research and engineering production is expected to be filled by flow chemistry technology, which relies on microreactors. Microreaction devices and technologies for synthesizing different kinds of nanocrystals are discussed from an engineering point of view. The advantages of microreactors, the important features of flow chemistry systems, and methods to apply them in the syntheses of salt, oxide, metal, alloy, and quantum dot nanomaterials are summarized. To further exhibit the scaling-up of nanocrystal synthesis, recent reports on using microreactors with gram per hour and larger production rates are highlighted. Finally, an industrial example for preparing 10 tons of CaCO₃ nanoparticles per day is introduced, which shows the great potential for flow chemistry processes to transfer lab research to industry.

Continuous production of iron oxide nanoparticles via fast and economical high temperature synthesis

A continuous, fast and economical high temperature synthesis of iron oxide nanoparticles was developed and compared to a conventional batch synthesis in terms of production costs.

Easily fabricated monolithic fluoropolymer chips for sensitive long-term absorbance measurement in droplet microfluidics

Maintaining a hydrophobic channel surface is critical to ensuring long-term stable flow in droplet microfluidics. Monolithic fluoropolymer chips ensure robust and reliable droplet flow as their native fluorous surfaces naturally preferentially wet fluorocarbon oils and do not deteriorate over time. Their fabrication, however, typically requires expensive heated hydraulic presses that make them inaccessible to many laboratories. Here we describe a method for micropatterning and bonding monolithic fluoropolymer flow cells from a commercially available melt-processable fluoropolymer, Dyneon THV 500GZ, that only requires a standard laboratory oven. Using this technique, we demonstrate the formation of complex microstructures, specifically the fabrication of sensitive absorbance flow cells for probing droplets in flow, featuring path lengths up to 10 mm. The native fluorous channel surface means the flow cells can be operated over extended periods, demonstrated by running droplets continuously through a chip for 16 weeks.

We present a widely accessible method for fabricating monolithic fluoropolymer microfluidic chips, which allows droplet absorbance measurement over multi-month periods.

Droplet microfluidics: from proof-of-concept to real-world utility?

Droplet microfluidics constitutes a diverse and practical tool set that enables chemical and biological experiments to be performed at high speed and with enhanced efficiency when compared to conventional instrumentation. Indeed, in recent years, droplet-based microfluidic tools have been used to excellent effect in a range of applications, including materials synthesis, single cell analysis, RNA sequencing, small molecule screening, in vitro diagnostics and tissue engineering. Our 2011 Chemical Communications Highlight Article [Chem. Commun., 2011, 47, 1936-1942] reviewed some of the most important technological developments and applications of droplet microfluidics, and identified key challenges that needed to be addressed in the short term. In the current contribution, we consider the intervening eight years, and assess the contributions that droplet-based microfluidics has made to experimental science in its broadest sense.

Microfluidic assisted synthesis of PLGA drug delivery systems

Poly(lactic-co-glycolic acid) (PLGA) is a biocompatible and biodegradable polymer that recently attracted attention for use as part of drug delivery systems (DDS). In this context, there is an emerging need for a rapid, reliable and reproducible method of synthesis. Here, microfluidic systems provide great opportunities for synthesizing carriers in a tightly controlled manner and with low consumption of materials, energy and time. These miniature devices have been the focus of recent research since they can address the challenges inherent to the bulk system, e.g. low drug loading efficiency and encapsulation, broad size distribution and burst initial release. In this article, we provide an overview of current microfluidic systems used in drug delivery production, with a special focus on PLGA-based DDS. In this context, we highlight the advantages associated with the use of microchip systems in the fabrication of nanoparticles (NPs) and microparticles (MPs), e.g. in achieving complex morphologies. Furthermore, we discuss the challenges for selecting proper microfluidics for targeted DDS production in a translational setting and introduce strategies that are used to overcome microfluidics shortcomings, like low throughput for production.

Poly(lactic-co-glycolic acid) (PLGA) is a biocompatible and biodegradable polymer that recently attracted attention for use as part of drug delivery systems (DDS).

Large-Scale Synthesis and Medical Applications of Uniform-Sized Metal Oxide Nanoparticles

Thanks to recent advances in the synthesis of high-quality inorganic nanoparticles, more and more types of nanoparticles are becoming available for medical applications. Especially, metal oxide nanoparticles have drawn much attention due to their unique physicochemical properties and relatively inexpensive production costs. To further promote the development and clinical translation of these nanoparticle-based agents, however, it is highly desirable to reduce unwanted interbatch variations of the nanoparticles because characterizing and refining each batch are costly, take a lot of effort, and, thus, are not productive. Large-scale synthesis is a straightforward and economic pathway to minimize this issue. Here, the recent achievements in the large-scale synthesis of uniform-sized metal oxide nanoparticles and their biomedical applications are summarized, with a focus on nanoparticles of transition metal oxides and lanthanide oxides, and clarifying the underlying mechanism for the synthesis of uniform-sized nanoparticles. Surface modification steps to endow hydrophobic nanoparticles with water dispersibility and biocompatibility are also briefly described. Finally, various medical applications of metal oxide nanoparticles, such as bioimaging, drug delivery, and therapy, are presented.

Microfluidic fabrication of microparticles for biomedical applications

Droplet microfluidics offers exquisite control over the flows of multiple fluids in microscale, enabling fabrication of advanced microparticles with precisely tunable structures and compositions in a high throughput manner. The combination of these remarkable features with proper materials and fabrication methods has enabled high efficiency, direct encapsulation of actives in microparticles whose features and functionalities can be well controlled. These microparticles have great potential in a wide range of bio-related applications including drug delivery, cell-laden matrices, biosensors and even as artificial cells. In this review, we briefly summarize the materials, fabrication methods, and microparticle structures produced with droplet microfluidics. We also provide a comprehensive overview of their recent uses in biomedical applications. Finally, we discuss the existing challenges and perspectives to promote the future development of these engineered microparticles.

Exploration of Near-Infrared-Emissive Colloidal Multinary Lead Halide Perovskite Nanocrystals Using an Automated Microfluidic Platform

Hybrid organic-inorganic and fully inorganic lead halide perovskite nanocrystals (NCs) have recently emerged as versatile solution-processable light-emitting and light-harvesting optoelectronic materials. A particularly difficult challenge lies in warranting the practical utility of such semiconductor NCs in the red and infrared spectral regions. In this context, all three archetypal A-site monocationic perovskites-CH₃NH₃PbI₃, CH(NH₂)₂PbI₃, and CsPbI₃-suffer from either chemical or thermodynamic instabilities in their bulk form. A promising approach toward the mitigation of these challenges lies in the formation of multinary compositions (mixed cation and mixed anion). In the case of multinary colloidal NCs, such as quinary Cs _xFA_{1- x}Pb(Br_{1- y}I _y)₃ NCs, the outcome of the synthesis is defined by a complex interplay between the bulk thermodynamics of the solid solutions, crystal surface energies, energetics, dynamics of capping ligands, and the multiple effects of the reagents in solution. Accordingly, the rational synthesis of such NCs is a formidable challenge. Herein, we show that droplet-based microfluidics can successfully tackle this problem and synthesize Cs _xFA_{1- x}PbI₃ and Cs _xFA_{1- x}Pb(Br_{1- y}I _y)₃ NCs in both a time- and cost-efficient manner. Rapid in situ photoluminescence and absorption measurements allow for thorough parametric screening, thereby permitting precise optical engineering of these NCs. In this showcase study, we fine-tune the photoluminescence maxima of such multinary NCs between 700 and 800 nm, minimize their emission line widths (to below 40 nm), and maximize their photoluminescence quantum efficiencies (up to 89%) and phase/chemical stabilities. Detailed structural analysis revealed that the Cs _xFA_{1- x}Pb(Br_{1- y}I _y)₃ NCs adopt a cubic perovskite structure of FAPbI₃, with iodide anions partially substituted by bromide ions. Most importantly, we demonstrate the excellent transference of reaction parameters from microfluidics to a conventional flask-based environment, thereby enabling up-scaling and further implementation in optoelectronic devices. As an example, Cs _xFA_{1- x}Pb(Br_{1- y}I _y)₃ NCs with an emission maximum at 735 nm were integrated into light-emitting diodes, exhibiting a high external quantum efficiency of 5.9% and a very narrow electroluminescence spectral bandwidth of 27 nm.

A Droplet-Reactor System Capable of Automation for the Continuous and Scalable Production of Noble-Metal Nanocrystals

Noble-metal nanocrystals with well-controlled shapes or morphologies are of great interest for a variety of applications. To utilize these nanomaterials in consumer products, one has to produce the colloidal nanocrystals in large quantities while maintaining good control over their physical parameters and properties. Droplet reactors have shown great potential for the continuous and scalable production of colloidal nanocrystals with controlled shapes. However, the efficiencies of most previously reported systems are still limited because of the complex post-treatment procedures. For example, the mixture of silicone oil and an aqueous suspension of solid products has to be separated by leveraging their miscibility and difference in density, while the solid products often need to be purified and concentrated by centrifugation. Herein, we report the design and construction of a droplet-reactor system that include new features such as a homemade unit for the automatic separation of silicone oil from the aqueous phase as well as a cross-flow filtration unit for the effective purification and concentration of the nanocrystals. Using various types of Pd nanocrystals as examples, we have demonstrated the feasibility of using this system to automatically produce and collect samples with uniform sizes and well-controlled shapes.

Textured surfaces as a new platform for nanoparticle synthesis

We present a new, surface-based microfluidic platform for the synthesis of nanoparticles. In this platform chemical reagents are carried in separate droplets, then mixed and later transported to a desired location on the surface using surface textured ratchet tracks. This brings the advantages of both synthesizing and transporting nanoparticles in situ without having cross-contamination between samples and addressing each sample independently. This platform is also capable of carrying multiple synthesis reactions concurrently.

Unveiling the Shape Evolution and Halide-Ion-Segregation in Blue-Emitting Formamidinium Lead Halide Perovskite Nanocrystals Using an Automated Microfluidic Platform

Hybrid organic-inorganic perovskites and in particular formamidinium lead halide (FAPbX₃, X = Cl, Br, I) perovskite nanocrystals (NCs) have shown great promise for their implementation in optoelectronic devices. Specifically, the Br and I counterparts have shown unprecedented photoluminescence properties, including precise wavelength tuning (530-790 nm), narrow emission linewidths (<100 meV) and high photoluminescence quantum yields (70-90%). However, the controlled formation of blue emitting FAPb(Cl_1-xBr_x)₃ NCs lags behind their green and red counterparts and the mechanism of their formation remains unclear. Herein, we report the formation of FAPb(Cl_1-xBr_x)₃ NCs with stable emission between 440 and 520 nm in a fully automated droplet-based microfluidic reactor and subsequent reaction upscaling in conventional laboratory glassware. The thorough parametric screening allows for the elucidation of parametric zones (FA-to-Pb and Br-to-Cl molar ratios, temperature, and excess oleic acid) for the formation of nanoplatelets and/or NCs. In contrast to CsPb(Cl_1-xBr_x)₃ NCs, based on online parametric screening and offline structural characterization, we demonstrate that the controlled synthesis of Cl-rich perovskites (above 60 at% Cl) with stable emission remains a challenge due to fast segregation of halide ions.

Insights in the Diffusion Controlled Interfacial Flow Synthesis of Au Nanostructures in a Microfluidic System

Continuous segmented flow interfacial synthesis of Au nanostructures is demonstrated in a microchannel reactor. This study brings new insights into the growth of nanostructures at continuous interfaces. The size as well as the shape of the nanostructures showed significant dependence on the reactant concentrations, reaction time, temperature, and surface tension, which actually controlled the interfacial mass transfer. The microchannel reactor assisted in achieving a high interfacial area, as well as uniformity in mass transfer effects. Hexagonal nanostructures were seen to be formed in synthesis times as short as 10 min. The wettability of the channel showed significant effect on the particle size as well as the actual shape. The hydrophobic channel yielded hexagonal structures of relatively smaller size than the hydrophilic microchannel, which yielded sharp hexagonal bipyramidal particles (diagonal distance of 30 nm). The evolution of particle size and shape for the case of hydrophilic microchannel is also shown as a function of the residence time. The interfacial synthesis approach based on a stable segmented flow promoted an excellent control on the reaction extent, reduction in axial dispersion as well as the particle size distribution.

Controllable synthesis of nanocrystals in droplet reactors

In recent years, a broad range of nanocrystals have been synthesized in droplet-based microfluidic reactors which provide obvious advantages, such as accurate manipulation, better reproducibility and reliable automation. In this review, we initially introduce general concepts of droplet reactors followed by discussions of their main functional regions including droplet generation, mixing of reactants, reaction controlling, in situ monitoring, and reaction quenching. Subsequently, the enhanced mass and heat transport properties are discussed. Next, we focus on research frontiers including sequential multistep synthesis, intelligent synthesis, reliable scale-up synthesis, and interfacial synthesis. Finally, we end with an outlook on droplet reactors, especially highlighting some aspects such as large-scale production, the integrated process of synthesis and post-synthetic treatments, automated droplet reactors with in situ monitoring and optimizing algorithms, and rapidly developing strategies for interfacial synthesis.

Sequential Coalescence Enabled Two-Step Microreactions in Triple-Core Double-Emulsion Droplets Triggered by an Electric Field

Advances in microfluidic emulsification have enabled the generation of exquisite multiple-core droplets, which are promising structures to accommodate microreactions. An essential requirement for conducting reactions is the sequential coalescence of the multiple cores encapsulated within these droplets, therefore, mixing the reagents together in a controlled sequence. Here, a microfluidic approach is reported for the conduction of two-step microreactions by electrically fusing three cores inside double-emulsion droplets. Using a microcapillary glass device, monodisperse water-in-oil-in-water droplets are fabricated with three compartmented reagents encapsulated inside. An AC electric field is then applied through a polydimethylsiloxane chip to trigger the sequential mixing of the reagents, where the precise sequence is guaranteed by the discrepancy of the volume or conductivity of the inner cores. A two-step reaction in each droplet is ensured by two times of core coalescence, which totally takes 20-40 s depending on varying conditions. The optimal parameters of the AC signal for the sequential fusion of the inner droplets are identified. Moreover, the capability of this technique is demonstrated by conducting an enzyme-catalyzed reaction used for glucose detection with the double-emulsion droplets. This technique should benefit a wide range of applications that require multistep reactions in micrometer scale.

Microfluidic Technology: Uncovering the Mechanisms of Nanocrystal Nucleation and Growth

The controlled and reproducible formation of colloidal semiconductor nanocrystals (or quantum dots) is of central importance in nanoscale science and technology. The tunable size- and shape-dependent properties of such materials make them ideal candidates for the development of efficient and low-cost displays, solar cells, light-emitting devices, and catalysts. The formidable difficulties associated with the macroscale preparation of semiconductor nanocrystals (possessing bespoke optical and chemical properties) result from the fact that underlying reaction mechanisms are complex and that the reactive environment is difficult to control. Automated microfluidic reactors coupled with monitoring systems and optimization algorithms aim to elucidate complex reaction mechanisms that govern both nucleation and growth of nanocrystals. Such platforms are ideally suited for the efficient optimization of reaction parameters, assuring the reproducible synthesis of nanocrystals with user-defined properties. This Account aims to inform the nanomaterials community about how microfluidic technologies can supplement flask experimentation for the ensemble investigation of formation mechanisms and design of semiconductor nanocrystals. We present selected studies outlining the preparation of quantum dots using microfluidic systems with integrated analytics. Such microfluidic reaction systems leverage the ability to extract real-time information regarding optical, structural, and compositional characteristics of quantum dots during nucleation and growth stages. The Account further highlights our recent research activities focused on the development and application of droplet-based microfluidics with integrated optical detection systems for the efficient and rapid screening of reaction conditions and a better understanding of the mechanisms of quantum dot synthesis. We describe the features and operation of fully automated microfluidic reactors and their subsequent application to high-throughput parametric screening of metal chalcogenides (CdSe, PbS, PbSe, CdSeTe), ternary and core/shell heavy metal-free quantum dots (CuInS₂, CuInS₂/ZnS), and all-inorganic perovskite nanocrystals (CsPbX₃, X = Cl, Br, I) syntheses. Critically, concurrent absorption and photoluminescence measurements on millisecond to second time scales allow the extraction of basic parameters governing nanocrystal formation. Moreover, experimental data obtained from such microfluidic platforms can be directly supported by theoretical models of nucleation and growth. To this end, we also describe the use of metamodeling algorithms able to accurately predict optimized conditions of CdSe synthesis using a minimal number of sample parameters. Importantly, we discuss future challenges that must be addressed before microfluidic technologies are in a position to be widely adopted for the on-demand formation of nanocrystals. From a technology perspective, these challenges include the development of novel engineering platforms for the formation of complex architectures, the integration of monitoring systems able to harvest photophysical and structural information, the incorporation of continuous purification systems, and the application of optimization algorithms to multicomponent quantum dot systems.

Synthesis of Cesium Lead Halide Perovskite Nanocrystals in a Droplet-Based Microfluidic Platform: Fast Parametric Space Mapping

Prior to this work, fully inorganic nanocrystals of cesium lead halide perovskite (CsPbX3, X = Br, I, Cl and Cl/Br and Br/I mixed halide systems), exhibiting bright and tunable photoluminescence, have been synthesized using conventional batch (flask-based) reactions. Unfortunately, our understanding of the parameters governing the formation of these nanocrystals is still very limited due to extremely fast reaction kinetics and multiple variables involved in ion-metathesis-based synthesis of such multinary halide systems. Herein, we report the use of a droplet-based microfluidic platform for the synthesis of CsPbX3 nanocrystals. The combination of online photoluminescence and absorption measurements and the fast mixing of reagents within such a platform allows the rigorous and rapid mapping of the reaction parameters, including molar ratios of Cs, Pb, and halide precursors, reaction temperatures, and reaction times. This translates into enormous savings in reagent usage and screening times when compared to analogous batch synthetic approaches. The early-stage insight into the mechanism of nucleation of metal halide nanocrystals suggests similarities with multinary metal chalcogenide systems, albeit with much faster reaction kinetics in the case of halides. Furthermore, we show that microfluidics-optimized synthesis parameters are also directly transferrable to the conventional flask-based reaction.

Continuous synthesis of nanostructured silica based materials in a gas–liquid segmented flow tubular reactor

Synthesizing core–shell particles SiO₂@mSiO₂, mSiO₂and Au@SiO₂in a continuous tubular segmented reactor.

High temperature continuous flow synthesis of CdSe/CdS/ZnS, CdS/ZnS, and CdSeS/ZnS nanocrystals

Continuous flow reactors show great promise for large-scale synthesis of quantum dots. Here, we discuss results for the synthesis of multi-layered Cd-based hybrid nanocrystals - CdSe/CdS/ZnS, CdS/ZnS, and CdSeS/ZnS - in a continuous flow reactor. The simple reactor design and liquid-phase chemistry obviate the need for preheating or in-line mixing, and the chosen reactor dimensions and operating conditions allow for high flow rates (∼10 mL min(-1)). Additionally, the simple reactor design is well suited for scale-up. The CdSe/CdS/ZnS particles synthesized at elevated temperatures in the reactor exhibit quantum yields of over 60% at longer wavelengths (red region). The shell growth for these particles is conducted without the need for complex dropwise addition or SILAR shell growth procedures used in batch reactors. CdS-based particles were shown to have a higher performance when using octadecene-S instead of TOP-S, which improved the quality of shell growth. In addition, stoichiometric synthesis of the alternate CdSeS/ZnS alloy particles was conducted, removing the need for a large excess of S to offset the lower S reactivity. CdSeS/ZnS alloy nanoparticles exhibit quantum yields of about 50% in the intermediate wavelength range (500-600 nm).

Millisecond-Timescale Monitoring of PbS Nanoparticle Nucleation and Growth Using Droplet-Based Microfluidics

The early-time kinetics (<1 s) of lead sulfide (PbS) quantum dot formation are probed using a novel droplet-based microfluidic platform, which allows for high-throughput and real-time optical analysis of the reactive process with millisecond time resolution. The reaction platform enables the concurrent investigation of the emission characteristics of PbS quantum dots and a real-time estimation of their size and concentration during nucleation and growth. These investigations reveal a two-stage mechanism for PbS nanoparticle formation. The first stage corresponds to the fast conversion of precursor species to PbS crystals, followed by the growth of the formed particles. The growth kinetics of the PbS nanoparticles follow the Lifshitz-Slyozov-Wagner model for Ostwald ripening, allowing direct estimation of the rate constants for the process. In addition, the extraction of absorption spectra of ultrasmall quantum dots is demonstrated for first time in an online manner. The droplet-based microfluidic platform integrated with online spectroscopic analysis provides a new tool for the quantitative extraction of high temperature kinetics for systems with rapid nucleation and growth stages.

Droplet-based microreactor for synthesis of water-soluble Ag₂S quantum dots

A droplet-based microreactor was used for synthesis of water-soluble Ag2S quantum dots (QDs). Monodispersed Ag2S nanoparticles with a surface of carboxylic acid-terminated were synthesized in the droplet microreactor. The x-ray powder diffraction results indicated products were monoclinic Ag2S nanocrystals. Furthermore, different-sized Ag2S QDs that were near-infrared-emitting or visible-emitting were continuously stably synthesized in droplet microreactors at different temperatures. We believe we offer a new method for obtaining different-sized Ag2S nanoparticles.

Implementation of in situ SAXS/WAXS characterization into silicon/glass microreactors

A successful implementation of in situ X-ray scattering analysis of synthetized particle materials in silicon/glass microreactors is reported. Calcium carbonate (CaCO3) as a model material was precipitated inside the microchannels through the counter-injection of two aqueous solutions, containing carbonate ions and calcium ions, respectively. The synthesized calcite particles were analyzed in situ in aqueous media by combining Small Angle X-ray Scattering (SAXS) and Wide Angle X-ray Scattering (WAXS) techniques at the ESRF ID02 beam line. At high wavevector transfer, WAXS patterns clearly exhibit different scattering features: broad scattering signals originating from the solvent and the glass lid of the chip, and narrow diffraction peaks coming from CaCO3 particles precipitated rapidly inside the microchannel. At low wavevector transfer, SAXS reveals the rhombohedral morphology of the calcite particles together with their micrometer size without any strong background, neither from the chip nor from the water. This study demonstrates that silicon/glass chips are potentially powerful tools for in situ SAXS/WAXS analysis and are promising for studying the structure and morphology of materials in non-conventional conditions like geological materials under high pressure and high temperature.

Toward continuous and scalable production of colloidal nanocrystals by switching from batch to droplet reactors

Droplet reactors serve as a practical platform to the scalable production of colloidal nanocrystals with well-controlled sizes, shapes, and structures.

Continuous and scalable production of well-controlled noble-metal nanocrystals in milliliter-sized droplet reactors

Noble-metal nanocrystals are essential to applications in a variety of areas, including catalysis, electronics, and photonics. Despite the large number of reports, there still exists a gap between academic studies and industrial applications due to the lack of ability to produce the nanocrystals in large quantities while still maintaining the good uniformity and precise controls. Because the nucleation and growth of colloidal nanocrystals are highly sensitive to experimental conditions, it is impractical to scale up their production by simply increasing the reaction volume. Here we report a new and practical approach based on milliliter-sized droplet reactors to the scalable production of nanocrystals. The droplets of 0.25 mL in volume were produced as a continuous flow in a fluidic device assembled from commercially available components. As a proof of concept, we have synthesized Pd, Au, and Pd-M (M = Au, Pt, and Ag) nanocrystals with controlled sizes, shapes, compositions, and structures on a scale of 1-10 g per hour (e.g., 3.6 g per hour for Pd cubes of 10 nm in edge length).

Nanocrystal synthesis in microfluidic reactors: where next?

The past decade has seen a steady rise in the use of microfluidic reactors for nanocrystal synthesis, with numerous studies reporting improved reaction control relative to conventional batch chemistry. However, flow synthesis procedures continue to lag behind batch methods in terms of chemical sophistication and the range of accessible materials, with most reports having involved simple one- or two-step chemical procedures directly adapted from proven batch protocols. Here we examine the current status of microscale methods for nanocrystal synthesis, and consider what role microreactors might ultimately play in laboratory-scale research and industrial production.

Real-time analysis of diaquat dibromide monohydrate in water with a SERS-based integrated microdroplet sensor

We report the fast and sensitive trace analysis of diaquat dibromide monohydrate (DQ) in water using a surface-enhanced Raman scattering (SERS)-based microdroplet sensor. This sensor is composed of two compartments: the first one is for droplet generation for fresh silver nanoparticle (AgNP) synthesis and the second for droplet merging for SERS detection. Silver ions were nucleated and grown to large size AgNPs in droplets, and then each droplet was synchronously merged with another droplet containing DQ for SERS detection. This two-phase liquid-liquid segmented flow system prevented memory effects caused by the precipitation of nanoparticle aggregates on channel walls because the aqueous droplets were isolated by a continuous oil phase. The limit of detection (LOD) of DQ in water was determined to be below 5 nM, which satisfies the maximum contaminant level defined by the United States EPA. This method was also validated successfully in DQ-spiked tap water. The SERS-based integrated sensing system is expected to be useful as an in-the-field sensing platform for fast and reproducible trace analysis of environmental pollutants in water.

Synthesis of colloidal metal nanocrystals in droplet reactors: the pros and cons of interfacial adsorption

Droplet reactors have received considerable attention in recent years as an alternative route to the synthesis and potentially high-volume production of colloidal metal nanocrystals. Interfacial adsorption will immediately become an important issue to address when one seeks to translate a nanocrystal synthesis from batch reactors to droplet reactors due to the involvement of higher surface-to-volume ratios for the droplets and the fact that nanocrystals tend to be concentrated at the water-oil interface. Here we report a systematic study to compare the pros and cons of interfacial adsorption of metal nanocrystals during their synthesis in droplet reactors. On the one hand, interfacial adsorption can be used to generate nanocrystals with asymmetric shapes or structures, including one-sixth-truncated Ag octahedra and Au-Ag nanocups. On the other hand, interfacial adsorption has to be mitigated to obtain nanocrystals with uniform sizes and controlled shapes. We confirmed that Triton X-100, a nonionic surfactant, could effectively alleviate interfacial adsorption while imposing no impact on the capping agent typically needed for a shape-controlled synthesis. With the introduction of a proper surfactant, droplet reactors offer an attractive platform for the continuous production of colloidal metal nanocrystals.

Microsystem-assisted synthesis of carbon dots with fluorescent and colorimetric properties for pH detection

The present paper describes the use of a microfluidic system to synthesize carbon dots (Cdots) and their use as optical pH sensors. The synthesis is based on the thermal decomposition of ascorbic acid in dimethyl sulfoxide. The proposed microsystem is composed of a fluidic and a thermal platform, which enable proper control of synthesis variables. Uniform and monodispersed 3.3 nm-sized Cdots have been synthesized, the optical characterization of which showed their down/upconversion luminescence and colorimetric properties. The obtained Cdots have been used for pH detection with down and upconverison fluorescent properties as excitation sources. The naked eye or a photographic digital camera has also been implemented as detection systems with the hue parameter showing a linear pH range from 3.5 to 10.2. On the other hand, experiments on the cytotoxicity and permeability of the Cdots on human embryonic kidney cells revealed their adsorption on cells without causing any impact on the cellular morphology.