Nanoengineering a library of metallic nanostructures using a single microfluidic reactor

Microfluidic Synthesis of Multifunctional Micro-/Nanomaterials from Process Intensification: Structural Engineering to High Electrochemical Energy Storage

Multifunctional micro-/nanomaterials featuring functional superiority and high value-added physicochemical nature have received immense attention in electrochemical energy storage. Microfluidic synthesis has become an emergent technology for massively producing multifunctional micro-/nanomaterials with tunable microstructure and morphology due to its rapid mass/heat transfer and precise fluid controllability. In this review, the latest progresses and achievements in microfluidic-synthesized multifunctional micro-/nanomaterials are summarized via reaction process intensification, multifunctional micro-/nanostructural engineering and electrochemical energy storage applications. The reaction process intensification mechanisms of various micro-/nanomaterials, including quantum dots (QDs), metal materials, conducting polymers, metallic oxides, polyanionic compounds, metal-organic frameworks (MOFs) and two-dimensional (2D) materials, are discussed. Especially, the multifunctional structural engineering principles of as-fabricated micro-/nanomaterials, such as vertically aligned structure, heterostructure, core-shell structure, and tunable microsphere, are introduced. Subsequently, the electrochemical energy storage application of as-prepared multifunctional micro-/nanomaterials is clarified in supercapacitors, lithium-ion batteries, sodium-ion batteries, all-vanadium redox flow batteries, and dielectric capacitors. Finally, the current problems and future forecasts are illustrated.

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.

Preparation of Spherical Ultrafine Silver Particles Using Y-Type Microjet Reactor

Herein, micron-sized silver particles were prepared using the chemical reduction method by employing a Y-type microjet reactor, silver nitrate as the precursor, ascorbic acid as the reducing agent, and gelatin as the dispersion at room temperature (23 °C ± 2°C). Using a microjet reactor, the two reaction solutions collide and combine outside the reactor, thereby avoiding microchannel obstruction issues and facilitating a quicker and more convenient synthesis process. This study examined the effect of the jet flow rate and dispersion addition on the morphology and size of silver powder particles. Based on the results of this study, spherical and dendritic silver particles with a rough surface can be prepared by adjusting the flow rate of the reaction solution and gelatin concentration. The microjet flow rate of 75 mL/min and the injected gelatin amount of 1% of the silver nitrate mass produced spherical ultrafine silver particles with a size of 4.84 μm and a tap density of 5.22 g/cm³.

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.

Resolution-enhanced optical inspection system to examine metallic nanostructures using structured illumination

We developed a structured illumination-based optical inspection system to inspect metallic nanostructures in real time. To address this, we used post-image-processing techniques to enhance the image resolution. To examine the fabricated metallic nanostructures in real time, a compact and highly resolved optical inspection system was designed for practical industrial use. Structured illumination microscopy yields multiple images with various linear illumination patterns, which can be used to reconstruct resolution-enhanced images. Images of nanosized posts and complex structures reflected in the structured illumination were reconstructed into images with improved resolution. A comparison with wide-field images demonstrates that the optical inspection system exhibits high performance and is available as a real-time nanostructure inspection platform. Because it does not require special environmental conditions and enables multiple systems to be covered in arrays, the developed system is expected to provide real-time and noninvasive inspections during the production of large-area nanostructured components.

Toward continuous production of high-quality nanomaterials using microfluidics: nanoengineering the shape, structure and chemical composition

Over the last decade, a multitude of synthesis strategies has been reported for the production of high-quality nanoparticles. Wet-chemical methods are generally the most efficient synthesis procedures since high control of crystallinity and physicochemical properties can be achieved. However, a number of challenges remain from inadequate reaction control during the nanocrystallization process; specifically variability, selectivity, scalability and safety. These shortcomings complicate the synthesis, make it difficult to obtain a uniform product with desired properties, and present serious limitations for scaling the production of colloidal nanocrystals from academic studies to industrial applications. Continuous flow reactors based on microfluidic principles offer potential solutions and advantages. The reproducibility of reaction conditions in microfluidics and therefore product quality have proved to exceed those obtained by batch processing. Considering that in nanoparticles' production not only is it crucial to control the particle size distribution, but also the shape and chemical composition, this review presents an overview of the current state-of-the-art in synthesis of anisotropic and faceted nanostructures by using microfluidics techniques. The review surveys the available tools that enable shape and chemical control, including secondary growth methods, active segmented flow, and photoinduced shape conversion. In addition, emphasis is placed on the available approaches developed to tune the structure and chemical composition of nanomaterials in order to produce complex heterostructures in a continuous and reproducible fashion.

Understanding flow chemistry for the production of active pharmaceutical ingredients

Multi-step organic syntheses of various drugs, active pharmaceutical ingredients, and other pharmaceutically and agriculturally important compounds have already been reported using flow synthesis. Compared to batch, hazardous and reactive reagents can be handled safely in flow. This review discusses the pros and cons of flow chemistry in today’s scenario and recent developments in flow devices. The review majorly emphasizes on the recent developments in the flow synthesis of pharmaceutically important products in last five years including flibanserin, imatinib, buclizine, cinnarizine, cyclizine, meclizine, ribociclib, celecoxib, SC-560 and mavacoxib, efavirenz, fluconazole, melitracen HCl, rasagiline, tamsulosin, valsartan, and hydroxychloroquine. Critical steps and new development in the flow synthesis of selected compounds are also discussed.

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.

Design and synthesis of gold nanostars-based SERS nanotags for bioimaging applications

Surface-enhanced Raman spectroscopy (SERS) nanotags hold a unique place among bioimaging contrast agents due to their fingerprint-like spectra, which provide one of the highest degrees of detection specificity. However, in order to achieve a sufficiently high signal intensity, targeting capabilities, and biocompatibility, all components of nanotags must be rationally designed and tailored to a specific application. Design parameters include fine-tuning the properties of the plasmonic core as well as optimizing the choice of Raman reporter molecule, surface coating, and targeting moieties for the intended application. This review introduces readers to the principles of SERS nanotag design and discusses both established and emerging protocols of their synthesis, with a specific focus on the construction of SERS nanotags in the context of bioimaging and theranostics.

Scaling up the throughput of microfluidic droplet-based materials synthesis: A review of recent progress and outlook

The last two decades have witnessed tremendous progress in the development of microfluidic chips that generate micrometer- and nanometer-scale materials. These chips allow precise control over composition, structure, and particle uniformity not achievable using conventional methods. These microfluidic-generated materials have demonstrated enormous potential for applications in medicine, agriculture, food processing, acoustic, and optical meta-materials, and more. However, because the basis of these chips' performance is their precise control of fluid flows at the micrometer scale, their operation is limited to the inherently low throughputs dictated by the physics of multiphasic flows in micro-channels. This limitation on throughput results in material production rates that are too low for most practical applications. In recent years, however, significant progress has been made to tackle this challenge by designing microchip architectures that incorporate multiple microfluidic devices onto single chips. These devices can be operated in parallel to increase throughput while retaining the benefits of microfluidic particle generation. In this review, we will highlight recent work in this area and share our perspective on the key unsolved challenges and opportunities in this field.

Memory of chirality in a room temperature flow electrochemical reactor

Chiral compounds have become of great interest to the pharmaceutical industry as they possess various biological activities. Concurrently, the concept of “memory of chirality” has been proven as a powerful tool in asymmetric synthesis, while flow chemistry has begun its rise as a new enabling technology to add to the ever increasing arsenal of techniques available to the modern day chemist. Here, we have employed a new simple electrochemical microreactor design to oxidise an l-proline derivative at room temperature in continuous flow. Compared to batch, organic electrosynthesis via microflow reactors are advantageous because they allow shorter reaction times, optimization and scale up, safer working environments, and high selectivities (e.g. reduce overoxidation). Flow electrochemical reactors also provide high surface-to-volume ratios and impart the possibility of excluding the supporting electrolyte due to a very short interelectrode distance. By the comparison of Hofer Moest type electrochemical oxidations at room temperature in batch and flow, we conclude that continuous flow electrolysis is superior to batch, producing a good yield (71%) and a higher enantiomeric excess (64%). These results show that continuous flow has the potential to act as a new enabling technology for asymmetric synthesis to replace some aspects of conventional batch electrochemical processes.

Inorganic nanoparticle synthesis in flow reactors – applications and future directions

The use of flow technologies for obtaining nanoparticles can play an important role in the development of ecological and sustainable processes for obtaining inorganic nanomaterials, and the continuous methods are part of the Flow Chemistry trend.

Gas-Directed Production of Noble Metal-Magnetic Heteronanostructures in Continuous Fashion: Application in Catalysis

Complex nanomaterials produced by scale-up batch processes lack suitable control of shape, size distribution, chemical composition, and quality, because heat and mass transfer are seriously affected as the reactor volume increases. Here we use a novel continuous synthesis procedure, the active gas-liquid segmented flow, to produce noble metal-magnetic heteronanostructures with enormous interest in the fields of catalysis, biomedicine, environmental sensors, food monitoring, and chemical analysis. The microreactor technology proposed scales down the reaction volume to gain advantage of the large surface area to volume ratio with respect to conventional batch-type reactors, improving heat and mass transport and, consequently, promoting a uniform heating and mixing. The gas phase was introduced in the chemical reactor as gas slugs of nanoliter scale with a dual role: (1) passive mixing and (2) chemical directing agent to tune the crystallization of nanostructures in a continuous fashion. The shape, size, and magnetic properties of the resulting heteronanostructures, as well as the density, size, and composition of noble metal nanoparticles were tuned to show the versatility of the proposed approach in a timeline of 4 min. We demonstrated that the produced nanostructures provide excellent catalytic properties in the catalyzed hydrogenation of nitrophenols to aminophenols. Electron microscopy, UV-vis spectroscopy, and cyclic voltammetry studies showed the remarkable catalytic performance of the produced heteronanostructures.

Revealing the Formation Mechanism of Alloyed Pd-Ru Nanoparticles: A Conversion Measurement Approach Utilizing a Microflow Reactor

The synthesis of alloyed nanoparticles has been studied extensively; however, the formation mechanisms involved remain unclear. Here, we reveal the detailed formation mechanism of alloyed nanoparticles in a Pd-Ru system, using a semibatch polyol method in which the simultaneous rapid reduction of both precursors was assumed to be the critical mechanism. We employed a microflow reactor to realize rapid heating and cooling. A significant difference in the reaction rate between the two precursors was observed. Pd was reduced within seconds, but the reduction of Ru was 2 orders of magnitude slower than that of Pd and was not as rapid as previously assumed. Further investigation of the semibatch method was performed to trace changes in the particle sizes and composition. Through quantitative and multilateral evidence, we concluded that the formation of low-crystallinity seeds, followed by solid-state diffusion, is the governing mechanism for the formation of alloyed Pd-Ru nanoparticles.

Trapping shape-controlled nanoparticle nucleation and growth stages via continuous-flow chemistry

Continuous flow chemistry is used to trap the nucleation and growth stages of platinum-nickel nano-octahedra with second time resolution and high throughputs to probe their properties ex situ. The growth starts from poorly crystalline particles (nucleation) at 5 seconds, to crystalline 1.5 nm particles bounded by the {111}-facets at 7.5 seconds, followed by truncation and further growth to octahedral nanoparticles at 20 seconds.

Towards the continuous production of Pt-based heterogeneous catalysts using microfluidic systems

The continuous production of Pt-based heterogeneous catalysts based on ultra-small (<2 nm) noble metal nanoparticles deposited on mesoporous ordered silica and their catalytic activity in VOC abatement are here reported. Microfluidic reactors can be used not only to enable the fast and controlled production of ultra-small Pt nanoparticles (NPs), but also alloyed NPs including PtPd, PtRu and PtRh can be formed in short residence times (between 60 s and 5 min). A novel continuous and homogeneous loading of these catalytic NPs on SBA-15 used as a mesoporous support is also here reported. This procedure eases the NP loading and minimizes washing post-treatments. A 12-fold decrease in the synthesis time was obtained when using this microfluidic reactor compared to the traditional batch production of Pt NPs. Microflow and batch type reactors yielded a Pt precursor conversion to generate Pt NPs with a 90% and 85% yield, respectively. Under the same conditions, the productivity of the microfluidic system (27 mg Pt NPs per h) was twice the one achieved in the conventional batch type reactor. The catalytic performance of the supported catalysts separately prepared by microfluidics and by conventional impregnation under the same conditions and with the same noble metal loading was also compared in the n-hexane abatement as a model of VOCs. Both catalysts were active in the VOC oxidation reaction but a 95% reduction in the catalyst synthesis time was obtained when using the catalysts produced in the microfluidic platform. For this reaction a long-term activity test was successfully carried out at 175 °C during 30 h on stream using the heterogeneous catalyst prepared by using the flow reactor.

Kinetically controlled synthesis of bimetallic nanostructures by flowrate manipulation in a continuous flow droplet reactor

We show that different Au–Pd nanoparticles, ranging from sharp-branched octopods to core@shell octahedra, can be achieved by inline manipulation of reagent flowrates in a microreactor for seeded growth.

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.

Synthesis, Functionalization, and Design of Magnetic Nanoparticles for Theranostic Applications

In order to translate nanotechnology into medical practice, magnetic nanoparticles (MNPs) have been presented as a class of non-invasive nanomaterials for numerous biomedical applications. In particular, MNPs have opened a door for simultaneous diagnosis and brisk treatment of diseases in the form of theranostic agents. This review highlights the recent advances in preparation and utilization of MNPs from the synthesis and functionalization steps to the final design consideration in evading the body immune system for therapeutic and diagnostic applications with addressing the most recent examples of the literature in each section. This study provides a conceptual framework of a wide range of synthetic routes classified mainly as wet chemistry, state-of-the-art microfluidic reactors, and biogenic routes, along with the most popular coating materials to stabilize resultant MNPs. Additionally, key aspects of prolonging the half-life of MNPs via overcoming the sequential biological barriers are covered through unraveling the biophysical interactions at the bio-nano interface and giving a set of criteria to efficiently modulate MNPs' physicochemical properties. Furthermore, concepts of passive and active targeting for successful cell internalization, by respectively exploiting the unique properties of cancers and novel targeting ligands are described in detail. Finally, this study extensively covers the recent developments in magnetic drug targeting and hyperthermia as therapeutic applications of MNPs. In addition, multi-modal imaging via fusion of magnetic resonance imaging, and also innovative magnetic particle imaging with other imaging techniques for early diagnosis of diseases are extensively provided.

Multistage extraction platform for highly efficient and fully continuous purification of nanoparticles

This paper presents a fully-continuous novel liquid-liquid-extraction (LLE) platform for the purification of nanoparticles. The use of multistage operation enhances the purity of the final stream without the expense of high solvent consumption. Two case studies, purification of CdSe quantum dots in organic solvent and that of gold nanoparticles in water, demonstrate that the LLE platform is versatile, non-destructive, and highly efficient.

Microfluidic Synthesis of Nanohybrids

Nanohybrids composed of two or more components exhibit many distinct physicochemical properties and hold great promise for applications in optics, electronics, magnetics, new energy, environment protection, and biomedical engineering. Microfluidic systems exhibit many advantages due to their unique characteristics of narrow channels, variable length, controllable number of channels and multiple integrations. Particularly their spatial-temporarily splitting of the formation stages during nanomaterials formation along the microfluidic channels favors the online control of the reaction kinetic parameters and in situ tuning of the product properties. This Review is focused on the features of the current types of microfluidic devices in the synthesis of different types of nanohybrids based on the classification of the four main kinds of materials: metal, nonmetal inorganic, polymer and composites. Their morphologies, compositions and properties can be adjusted conveniently in these synthesis systems. Synthesis advantages of varieties of microfluidic devices for specific nanohybrids of defined surfaces and interfaces are presented according to their process and microstructure features of devices as compared with conventional methods. A summary is presented, and challenges are put forward for the future development of the microfluidic synthesis of nanohybrids for advanced applications.

Design protocol of microjet mixers for achieving desirable mixing times with arbitrary flow rate ratios

We extensively examined the performance of microjet mixers.

Advanced reactor engineering with 3D printing for the continuous-flow synthesis of silver nanoparticles

3D printing has been employed to manufacture advanced reactor geometries based on miniaturised continuous-flow oscillatory baffled reactors (mCOBRs) and they have been applied for the fouling free continuous-flow synthesis of silver nanoparticles with optimal size control.