Production of monodisperse drops from viscous fluids

3D printing of monolithic gravity-assisted step-emulsification device for scalable production of high viscosity emulsion droplets

Microfluidic technology widely used in generating monodisperse emulsion droplets often suffers from complexity, scalability, applicability to practical fluids, as well as operation instability due to its susceptibility to flow perturbations, low clearance, and depletion of surfactants. Herein, we present a monolithic 3D-printed step-emulsification device (3D-PSD) for scalable and robust production of high viscosity emulsion droplets up to 208.16 mPa s, which cannot be fully addressed using conventional step-emulsification devices. By utilizing stereo-lithography (SLA), 24 triangular nozzles with a pair of 3D void flow distributors are integrated within the 3D-PSD to ensure uniform flow distribution followed by monodisperse droplet formation. The outlets positioned vertically downward enables gravity-assisted clearing to prevent droplet accumulation and thereby maintain size monodispersity. Deposition of silica nanoparticles (SiNP) within the device was also shown to alter the surface wettability from hydrophobic to hydrophilic, enabling the production of both water-in-oil (W/O) as well as oil-in-water (O/W) emulsion droplets, operated at a maximum production rate of up to 50 mL h-1. The utility of the device is further verified through continuous production of biodegradable polycaprolactone (PCL) microparticles using O/W emulsion as templates. We envision that the 3D-PSD presented in this work marks a significant leap in high-throughput production of high viscosity emulsion droplets as well as the particle analogs.

Gas-assisted microfluidic step-emulsification for generating micron- and submicron-sized droplets

Micron- and submicron-sized droplets have extensive applications in biomedical diagnosis and drug delivery. Moreover, accurate high-throughput analysis requires a uniform droplet size distribution and high production rates. Although the previously reported microfluidic coflow step-emulsification method can be used to generate highly monodispersed droplets, the droplet diameter (d) is constrained by the microchannel height (b), d ≳ 3 b , while the production rate is limited by the maximum capillary number of the step-emulsification regime, impeding emulsification of highly viscous liquids. In this paper, we report a novel, gas-assisted coflow step-emulsification method, where air serves as the innermost phase of a precursor hollow-core air/oil/water emulsion. Air gradually diffuses out, producing oil droplets. The size of the hollow-core droplets and the ultrathin oil layer thickness both follow the scaling laws of triphasic step-emulsification. The minimal droplet size attains d ≈ 1.7 b , inaccessible in standard all-liquid biphasic step-emulsification. The production rate per single channel is an order-of-magnitude higher than that in the standard all-liquid biphasic step-emulsification and is also superior to alternative emulsification methods. Due to low gas viscosity, the method can also be used to generate micron- and submicron-sized droplets of high-viscosity fluids, while the inert nature of the auxiliary gas offers high versatility.

Microfluidic dual picoinjection based encapsulation of hemoglobin in alginate microcapsules reinforced by a poly(L-lysine)-g-poly(ethylene glycol)

Hemoglobin (Hb) encapsulation inside polysaccharide hydrogels has been considered a possible red blood cell (RBC) surrogate in transfusiology. Here we report on the microfluidic dual picoinjection assisted synthesis of Hb encapsulated alginate-poly(L-lysine)-g-poly(ethylene glycol) beads. This process is realized by the on-chip injections of blended Hb alginate solutions in emulsified aqueous calcium chloride (CaCl₂) droplets followed by a subsequent injection of an aqueous PLL-g-PEG into each emulsified aqueous droplet. The proposed fabrication approach was realized using a flow-focusing and two picoinjection sites in a single PDMS device. Aqueous CaCl₂ solution was emulsified and infused with Hb-alginate solution as the squeezed droplet passed through the first picoinjection site. The injection of PLL-g-PEG to reinforce the microgel and minimize the protein leaching was realized in the second picoinjection site located downstream from the first in the same microfluidic channel. In this process, monodisperse Hb-alginate-PLL-g-PEG particles with a diameter around the size of RBCs (9 μm) were obtained with around 80% of the 7.5 mg ml^-1 Hb included in the injected aqueous alginate retaining in the obtained microparticles. Microparticles with Hb loading (32.8 pg per bead) and retention (28.8 pg per bead) over a week of storage at 4 °C are in accordance with the average amount of Hb per RBC. The Hb-alginate-PLL-g-PEG microbeads fabricated in the size range of RBCs are significant for further exploration.

Parallelization of Microfluidic Droplet Junctions for Ultraviscous Fluids

The parallelization of multiple microfluidic droplet junctions has been successfully achieved so that the production throughput of the uniform microemulsions/particles has witnessed considerable progress. However, these advancements have been observed only in the case of a low viscous fluid (viscosity of 10^-2 -10^-3 Pa s). This study designs and fabricates a microfluidic device, enabling a uniform micro-emulsification of an ultraviscous fluid (viscosity of 3.5 Pa s) with a throughput of ≈330 000 droplets per hour. Multiple T-junctions of a dispersed oil phase, split from a single inlet, are connected into the single post-crossflow channel of a continuous water phase. In the proposed device, the continuous water phase undergoes a series circuit, wherein the resistances are continuously accumulated. The independent corrugations of the dispersed oil phase channel, under the theoretical guidance, compromise such increased resistances; the ratio of water to oil flow rates at each junction becomes consistent across T-junctions. Owing to the design being based on a fully 2D interconnection, single-step soft lithography is sufficient for developing the full device. This easy-to-craft architecture contrasts with the previous approach, wherein complicated 3D interconnections of the multiple junctions are involved, thereby facilitating the rapid uptake of high throughput droplet microfluidics for experts and newcomers alike.

Fluid-Mediated Fabrication of Complex Assemblies

This Perspective accounts for recent progress in the directed control of interfacial fluid flows harnessed to assemble architected soft materials. We are focusing on the paradigmatic problem of free-surface flows in curable elastomers. These elastomers are initially liquid and cure into elastic solids whose shape is imparted by concomitant and competing phenomena: flow-induced deformations and curing. Particular attention is given to the role of capillary forces in these systems. Originating from the cohesive nature of liquids and thus favoring smooth interfaces, capillary forces can also promote the destabilization of interfaces, e.g., into droplets. In turn, such mechanical instabilities tend to grow into regular patterns, e.g., forming hexagonal lattices. We discuss how the universality, robustness, and ultimate regularity of these out-of-equilibrium processes could serve as a basis for new fabrication paradigms, where instabilities are directed to generate target architected solids obtained without each element laid in place by direct mechanized intervention.

Advanced microfluidic devices for fabricating multi-structural hydrogel microsphere

Hydrogel microspheres are a novel functional material, arousing much attention in various fields. Microfluidics, a technology that controls and manipulates fluids at the micron scale, has emerged as a promising method for fabricating hydrogel microspheres due to its ability to generate uniform microspheres with controlled geometry. With the development of microfluidic devices, more complicated hydrogel microspheres with multiple structures can be constructed. This review presents an overview of advances in microfluidics for designing and engineering hydrogel microspheres. It starts with an introduction to the features of hydrogel microspheres and microfluidic techniques, followed by a discussion of material selection for fabricating microfluidic devices. Then the progress of microfluidic devices for single-component and composite hydrogel microspheres is described, and the method for optimizing microfluidic devices is also given. Finally, this review discusses the key research directions and applications of microfluidics for hydrogel microsphere in the future.

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.

On the Determination of Mechanical Properties of Aqueous Microgels-Towards High-Throughput Characterization

Aqueous microgels are distinct entities of soft matter with mechanical signatures that can be different from their macroscopic counterparts due to confinement effects in the preparation, inherently made to consist of more than one domain (Janus particles) or further processing by coating and change in the extent of crosslinking of the core. Motivated by the importance of the mechanical properties of such microgels from a fundamental point, but also related to numerous applications, we provide a perspective on the experimental strategies currently available and emerging tools being explored. Albeit all techniques in principle exploit enforcing stress and observing strain, the realization differs from directly, as, e.g., by atomic force microscope, to less evident in a fluid field combined with imaging by a high-speed camera in high-throughput strategies. Moreover, the accompanying analysis strategies also reflect such differences, and the level of detail that would be preferred for a comprehensive understanding of the microgel mechanical properties are not always implemented. Overall, the perspective is that current technologies have the capacity to provide detailed, nanoscopic mechanical characterization of microgels over an extended size range, to the high-throughput approaches providing distributions over the mechanical signatures, a feature not readily accessible by atomic force microscopy and micropipette aspiration.

Double emulsions with ultrathin shell by microfluidic step-emulsification

Double emulsions with ultrathin shells are important in some biomedical applications, such as controlled drug release. However, the existing production techniques require two or more manipulation steps, or more complicated channel geometry, to form thin-shell double emulsions. This work presents a novel microfluidic tri-phasic step-emulsification device, with an easily fabricated double-layer PDMS channel, for production of oil-in-oil-in-water and water-in-water-in-oil double emulsions in a single step. The shell thickness is controlled by the flow rates and can reach 1.4% of the μm-size droplet diameter. Four distinct emulsification regimes are observed depending on the experimental conditions. A theoretical model for the tri-phasic step-emulsification is proposed to predict the boundaries separating the four regimes of emulsification in plane of two dimensionless capillary numbers, Ca. The theory yields two coupled nonlinear differential equations that can be solved numerically to find the approximate shape of the free interfaces in the shallow (Hele-Shaw) microfluidic channel. This approximation is then used as the initial guess for the more accurate finite element method solution, showing very good agreement with the experimental findings. This study demonstrates the feasibility of co-flow step-emulsification as a promising method to production of double (and multiple) emulsions and micro-capsules with ultrathin shells of controllable thickness.

Step emulsification in microfluidic droplet generation: mechanisms and structures

Step emulsification for micro- and nano-droplet generation is reviewed in brief, including the emulsion mechanisms and microfluidic devices.

Split or slip – passive generation of monodisperse double emulsions with cores of varying viscosity in microfluidic tandem step emulsification system

We investigate the role of viscosities on the formation of double emulsion in a microfluidic step emulsification system. Aqueous droplets of various viscosities and sizes were engulfed in fluorocarbon oil and subsequently transformed into double droplets in the microfluidic step emulsifying device. We identify two distinct regimes of double droplet formation: (i) core droplets split into multiple smaller droplets, or (ii) cores slip whole into the forming oil shell. We show that the viscosity ratio of the core and shell phases plays a crucial role in determining the mode of formation of the double emulsions. Finally, we demonstrate that high viscosity of the core droplet allows for generation of double emulsions with constant shell thickness for cores of various sizes.

We investigate the role of fluid viscosities on formation of double emulsion in a microfluidic step emulsification system. The ratio of fluid viscosities controls double droplet formation, leading to splitting of the core for low core-to-shell viscosity ratio.

Monodisperse droplet formation by spontaneous and interaction based mechanisms in partitioned EDGE microfluidic device

The partitioned EDGE droplet generation device is known for its’ high monodisperse droplet formation frequencies in two distinct pressure ranges, and an interesting candidate for scale up of microfluidic emulsification devices. In the current study, we test various continuous and dispersed phase properties and device geometries to unravel how the device spontaneously forms small monodisperse droplets (6–18 μm) at low pressures, and larger monodisperse droplets (>28 μm) at elevated pressures. For the small droplets, we show that the continuous phase inflow in the droplet formation unit largely determines droplet formation behaviour and the resulting droplet size and blow-up pressure. This effect was not considered as a factor of significance for spontaneous droplet formation devices that are mostly characterised by capillary numbers in literature. We then show for the first time that the formation of larger droplets is caused by physical interaction between neighbouring droplets, and highly dependent on device geometry. The insights obtained here are an essential step toward industrial emulsification based on microfluidic devices.

Grooved step emulsification systems optimize the throughput of passive generation of monodisperse emulsions

Microfluidic step emulsification passively produces highly monodisperse droplets and can be easily parallelized for high throughput emulsion production. The two main techniques used for step emulsification are: i) edge-based droplet generation (EDGE), where droplets are formed in a single, very wide and shallow nozzle, and ii) microchannel emulsification (MCE), where droplets are formed in many separated narrow nozzles. These techniques differ in modes of droplet formation that influence the throughput and monodispersity of produced emulsions. Here we report a systematic study of novel grooved step emulsifying geometries, a hybrid of MCE and EDGE architectures. We introduce partitions of different heights to a wide (EDGE-like) slit to establish optimal geometries for high-throughput droplet production. We demonstrate that the volume and monodispersity of the produced emulsion can be tuned solely by changing the height of these partitions. We show that the spacing of the partitions influences the size of the produced droplets, but not the population monodispersity. We also determine the moment of transition between two distinct droplet generation modes as a function of the geometrical parameters of the nozzle. The optimized grooved geometry appears to combine the advantages of both MCE and EDGE, i.e. spatial localization of droplet forming units (DFUs), high-throughput formation of tightly monodisperse droplets from parallel DFUs, and low sensitivity to variation in the flow rate of the dispersed phase. As a proof-of-concept we show grooved devices that for a 260-fold increase of flow rate produce droplets with volume increased by just 75%, as compared to 91% increase in volume over a 180-fold increase of flow rate of the dispersed phase in MCE devices. We also present the optimum microfluidic device geometry that almost doubles the throughput of an MCE device in the generation of nanoliter droplets.

Cross-talk between emulsion drops: how are hydrophilic reagents transported across oil phases?

Emulsion drops are frequently used as vessels, for example, to conduct biochemical reactions in small volumes or to perform screening assays at high throughputs while consuming minimal sample volumes. These applications typically require drops that do not allow exchange of reagents such that no cross-contamination occurs. Unfortunately, in many cases, reagents are exchanged between emulsion drops even if they have a low solubility in the surrounding phase, resulting in cross-contaminations. Here, we investigate the mechanism by which hydrophilic reagents are transported across an oil phase using water-oil-water double emulsion drops as a model system. Remarkably, even large objects, including 11 000 base pair double-stranded circular DNA are transported across oil shells. Importantly, this reagent transport, that is to a large extent caused by aqueous drops that spontaneously form at the water-oil interface, is not limited to double emulsions but also occurs between single emulsion drops. We demonstrate that the uncontrolled reagent transport can be decreased by at least an order of magnitude if appropriate surfactants that lower the interfacial tension only moderately are employed or if the shell thickness of double emulsions is decreased to a few hundreds of nanometers.

Scalable production of double emulsion drops with thin shells

Double emulsions are often used as containers to perform high throughput screening assays and as templates for capsules. These applications require double emulsions to be mechanically stable such that they do not coalesce during processing and storage. A possibility to increase their stability is to reduce the thickness of their shells to sufficiently low values that lubrication effects hinder coalescence. However, the controlled fabrication of double emulsions with such thin shells is difficult. Here, we introduce a new microfluidic device, the aspiration device, that reduces the shell thickness of double emulsions down to 240 nm at a high throughput; thereby, the shell volume is reduced by up to 95%. The shell thickness of the resulting double emulsions depends on the pressure profile in the device and hence on the fluid flow rates in the channels and is independent of the shell thickness of the injected double emulsions. Therefore, this device enables converting double emulsions with polydisperse shell thicknesses into double emulsions with well-defined, uniform thin shells.