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

Janus droplet microreactors for preparing polyaniline/AgCl nanocomposites

We report a novel method to conduct heterogeneous reactions using aqueous-ionic liquid Janus microdroplets as a series of isolated bi-phasic microreactors where AgCl@polyaniline core-shell nanoparticles are successfully synthesized accompanied by polyaniline nano-needles, and enhanced visualization of reaction progression through the color changes in Janus droplets is achieved.

Microfluidic strategies for engineering oxygen-releasing biomaterials

In the field of tissue engineering, local hypoxia in large-cell structures (larger than 1 mm3) poses a significant challenge. Oxygen-releasing biomaterials supply an innovative solution through oxygen ⁠ delivery in a sustained and controlled manner. Compared to traditional methods such as emulsion, sonication, and agitation, microfluidic technology offers distinct benefits for oxygen-releasing material production, including controllability, flexibility, and applicability. It holds enormous potential in the production of smart oxygen-releasing materials. This review comprehensively covers the fabrication and application of microfluidic-enabled oxygen-releasing biomaterials. To begin with, the physical mechanism of various microfluidic technologies and their differences in oxygen carrier preparation are explained. Then, the distinctions among diverse oxygen-releasing components in regards for oxygen-releasing mechanism, oxygen-carrying capacity, and duration of oxygen release are presented. Finally, the present obstacles and anticipated development trends are examined together with the application outcomes of oxygen-releasing biomaterials based on microfluidic technology in the biomedical area. STATEMENT OF SIGNIFICANCE: Oxygen is essential for sustaining life, and hypoxia (a condition of low oxygen) is a significant challenge in various diseases. Microfluidic-based oxygen-releasing biomaterials offer precise control and outstanding performance, providing unique advantages over traditional approaches for tissue engineering. However, comprehensive reviews on this topic are currently lacking. In this review, we provide a comprehensive analysis of various microfluidic technologies and their applications for developing oxygen-releasing biomaterials. We compare the characteristics of organic and inorganic oxygen-releasing biomaterials and highlight the latest advancements in microfluidic-enabled oxygen-releasing biomaterials for tissue engineering, wound healing, and drug delivery. This review may hold the potential to make a significant contribution to the field, with a profound impact on the scientific community.

Droplet Microfluidic Devices: Working Principles, Fabrication Methods, and Scale-Up Applications

Compared with the conventional emulsification method, droplets generated within microfluidic devices exhibit distinct advantages such as precise control of fluids, exceptional monodispersity, uniform morphology, flexible manipulation, and narrow size distribution. These inherent benefits, including intrinsic safety, excellent heat and mass transfer capabilities, and large surface-to-volume ratio, have led to the widespread applications of droplet-based microfluidics across diverse fields, encompassing chemical engineering, particle synthesis, biological detection, diagnostics, emulsion preparation, and pharmaceuticals. However, despite its promising potential for versatile applications, the practical utilization of this technology in commercial and industrial is extremely limited to the inherently low production rates achievable within a single microchannel. Over the past two decades, droplet-based microfluidics has evolved significantly, considerably transitioning from a proof-of-concept stage to industrialization. And now there is a growing trend towards translating academic research into commercial and industrial applications, primarily driven by the burgeoning demands of various fields. This paper comprehensively reviews recent advancements in droplet-based microfluidics, covering the fundamental working principles and the critical aspect of scale-up integration from working principles to scale-up integration. Based on the existing scale-up strategies, the paper also outlines the future research directions, identifies the potential opportunities, and addresses the typical unsolved challenges.

Microfluidics for personalized drug delivery

This review highlights the transformative impact of microfluidic technology on personalized drug delivery. Microfluidics addresses issues in traditional drug synthesis, providing precise control and scalability in nanoparticle fabrication, and microfluidic platforms show high potential for versatility, offering patient-specific dosing and real-time monitoring capabilities, all integrated into wearable technology. Covalent conjugation of antibodies to nanoparticles improves bioactivity, driving innovations in drug targeting. The integration of microfluidics with sensor technologies and artificial intelligence facilitates real-time feedback and autonomous adaptation in drug delivery systems. Key challenges, such as droplet polydispersity and fluidic handling, along with future directions focusing on scalability and reliability, are essential considerations in advancing microfluidics for personalized drug delivery.

Optimization of a tunable process for rapid production of calcium phosphate microparticles using a droplet-based microfluidic platform

Calcium phosphate (CaP) biomaterials are amongst the most widely used synthetic bone graft substitutes, owing to their chemical similarities to the mineral part of bone matrix and off-the-shelf availability. However, their ability to regenerate bone in critical-sized bone defects has remained inferior to the gold standard autologous bone. Hence, there is a need for methods that can be employed to efficiently produce CaPs with different properties, enabling the screening and consequent fine-tuning of the properties of CaPs towards effective bone regeneration. To this end, we propose the use of droplet microfluidics for rapid production of a variety of CaP microparticles. Particularly, this study aims to optimize the steps of a droplet microfluidic-based production process, including droplet generation, in-droplet CaP synthesis, purification and sintering, in order to obtain a library of CaP microparticles with fine-tuned properties. The results showed that size-controlled, monodisperse water-in-oil microdroplets containing calcium- and phosphate-rich solutions can be produced using a flow-focusing droplet-generator microfluidic chip. We optimized synthesis protocols based on in-droplet mineralization to obtain a range of CaP microparticles without and with inorganic additives. This was achieved by adjusting synthesis parameters, such as precursor concentration, pH value, and aging time, and applying heat treatment. In addition, our results indicated that the synthesis and fabrication parameters of CaPs in this method can alter the microstructure and the degradation behavior of CaPs. Overall, the results highlight the potential of the droplet microfluidic platform for engineering CaP microparticle biomaterials with fine-tuned properties.

Shape-memory microfluidic chips for fluid and droplet manipulation

Fluid manipulation is an important foundation of microfluidic technology. Various methods and devices have been developed for fluid control, such as electrowetting-on-dielectric-based digital microfluidic platforms, microfluidic pumps, and pneumatic valves. These devices enable precise manipulation of small volumes of fluids. However, their complexity and high cost limit the commercialization and widespread adoption of microfluidic technology. Shape memory polymers as smart materials can adjust their shape in response to external stimuli. By integrating shape memory polymers into microfluidic chips, new possibilities for expanding the application areas of microfluidic technology emerge. These shape memory polymers can serve as actuators or regulators to drive or control fluid flow in microfluidic systems, offering innovative approaches for fluid manipulation. Due to their unique properties, shape memory polymers provide a new solution for the construction of intelligent and automated microfluidic systems. Shape memory microfluidic chips are expected to be one of the future directions in the development of microfluidic technology. This article offers a summary of recent research achievements in the field of shape memory microfluidic chips for fluid and droplet manipulation and provides insights into the future development direction of shape memory microfluidic devices.

Understanding droplet breakup in a post-array device with sheath-flow configuration

Microfluidic post-array devices have the potential to generate quasi-monodisperse emulsion droplets with high throughput and dispersed phase fractions by splitting droplets with regularly arranged posts. However, the lack of understanding of post-array devices makes it challenging to predict droplet size and quantitatively evaluate the influence of post geometry, hindering their widespread application. Therefore, we investigated the characteristics of droplet breakup through a post array using a series of devices with sheath-flow configurations, in which the dispersed and continuous flow rates could be flexibly tuned. Using a poly(dimethylsiloxane)-glass device fabricated via soft lithography, we found that the volume ratio of the dispersed phase to the continuous phase significantly affects the droplet size, even when the viscosity ratio is close to one. For the first time, we demonstrated that the effective capillary number calculated from the emulsion viscosity and effect of the dispersed phase fraction consistently describes various experimental results. Furthermore, our flow observations and droplet diameter measurement showed two breakup modes: the size-constant obstruction and shear-induced modes with a power-law correlation similar to droplet splitting in a T-junction. Thus, the power-law correlation in microfluidic droplet splitting successfully expresses the droplet generation characteristics in post-array devices. A combination of effective viscosity correction and curve fitting allowed us to evaluate the influence of the material and post-geometry on droplet generation characteristics. This study contributes to the understanding of droplet breakup in post-array devices and extends their unique droplet generation properties to include high-throughput, high-fraction, robust, and continuous emulsification processes.

High-throughput fabrication of monodisperse spherical supraparticles through a reliable thin oil film and rapid water diffusion

A supraparticle is a spherical superstructure composed of fine building blocks, typically synthesized through colloidal assembly from evaporating and contracting suspension droplets. Microfluidic emulsification is known to be effective in producing large amounts of water-in-oil droplets. However, the process of supraparticle self-assembly has been limited by the evaporation of the oil that supports it and the sluggish shrinkage of water droplets. These are caused by the high volatility and low diffusion rates of water in the bulk oil layer, making the process last hours or even days. To address these challenges, we introduce a new system in this paper: the supraparticle reliable fabrication (SURF) system. This microfluidic-based system can quickly and reliably assemble spherical supraparticles in 20 min. The SURF system combines a conventional flow focusing device with a thinly layered low-volatile/water-soluble oil, and an open-microfluidic droplet evaporator. This setup facilitates the creation of uniform supraparticles with various materials and diameters (coefficient of variation: <3.5%). As a proof-of-concept for potential biochemical applications, we demonstrate a sensitive chemical reaction on the fabricated supraparticles, emphasizing the effectiveness of the SURF system as an alternative to traditional supraparticle synthesis and particle-based applications.

Throughput-scalable manufacturing of SARS-CoV-2 mRNA lipid nanoparticle vaccines

Lipid nanoparticles (LNPs) are a potent delivery technology that have made it possible for the recent clinical breakthroughs in mRNA therapeutics and vaccines. A key challenge to the broader implementation of mRNA therapeutics and vaccines is the development of technology to produce precisely defined LNP formulations, with throughput that can scale from discovery to commercial manufacturing and meet the stringent manufacturing standards of the pharmaceutical industry. To address these challenges, we have developed a microfluidic chip that incorporates 1×, 10×, or 256× LNP-generating units that achieve scalable production rates of up to 17 L/h of precisely defined LNPs. Using these chips, we demonstrate that LNP physical properties and potency in vivo are unchanged as throughput is scaled. Our chips are fabricated out of silicon and glass substrates, which have excellent solvent compatibility, compatibility with pharmaceutical manufacturing, and can be fully reset and reused. SARS-CoV-2 mRNA-LNP vaccines formulated by our chips triggered potent antibody responses in a preclinical study. These results demonstrate the feasibility of directly translating microfluidic-generated LNPs to the scale necessary for commercial production.

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.

Modulation of Oil/Polymer Nanocapsule Size via Phase Diagram-Guided Microfluidic Coprecipitation

Flow-based nanoprecipitation of different solutes via rapid mixing of two miscible liquids is a scalable strategy for manufacturing nanoparticles with various shapes and morphologies. Controlling the size of nanoparticles in flow-based nanoprecipitation, however, is often left to empirical variations in the flow rate ratios or the total flow rate of the two streams. In this work, we investigate the coprecipitations of oil and polymer to form nanocapsules via the Ouzo effect using glass capillary microfluidics across a range of mixing conditions. In the range of flow rates studied, the two streams mix convectively in micro-vortices formed at the junction of the two stream inlets. Using computational fluid dynamics simulations and glass capillary microfluidic nanoprecipitation, we establish a relationship between the precipitation conditions occurring experimentally in situ and the location on the ternary Ouzo phase diagram where precipitation is taking place. We find that a key variable in the resulting average diameter of the fabricated capsules is the degree of supersaturation experienced by both the oil and the polymer in the vortex zone of the device, showing a strong correlation between the two values. The control over the nanocapsule size by varying the extent of supersaturation of both precipitants is demonstrated by using two oils having distinct phase diagrams. This work provides a systematic approach to controlling the size of nanoparticles fabricated via continuous nanoprecipitation by linking the in situ flow conditions to ternary phase diagram behavior, enabling accurate control over nanocapsule size.

Application of droplet migration scaling behavior to microchannel flow measurements

In confined channels in low Reynolds number flow, droplets drift perpendicular to the flow, moving across streamlines. The phenomenon has proven useful for understanding microfluidic droplet separation, drug delivery vehicle optimization, and single-cell genomic amplification. Particles or droplets undergo several migration mechanisms including wall migration, hydrodynamic diffusion, and migration down gradients of shear. In simple shear flow only wall migration and hydrodynamic diffusion are present. In parabolic flow, droplets also move down gradients of shear. The resulting separation depends on parameters including particle size and stiffness, concentration, and flow rate. Computational methods can incorporate these effects in an exact manner to predict margination phenomena for specific systems, but do not generate a descriptive parametric dependence. In this paper, we present a scaling model that elucidates the parametric dependence of margination on emulsion droplet size, volume fraction, shear rate and suspending fluid viscosity. We experimentally measure the droplet depletion layer of silicone oil droplets and compare the results to theoretical scaling behavior that includes hydrodynamic diffusion and wall migration with and without an added shear-gradient migration. Results demonstrate the viability and limitations of applying a simple scaling behavior to experimental systems to describe parametric dependence. Our conclusions open the possibility for parametric descriptions of migration with broad applicability to particle and droplet systems.

Droplet microfluidics for CTC-based liquid biopsy: a review

Circulating tumor cells (CTCs) are important biomarkers of liquid biopsy. The number and heterogeneity of CTCs play an important role in cancer diagnosis and personalized medicine. However, owing to the low-abundance biomarkers of CTCs, conventional assays are only able to detect CTCs at the population level. Therefore, there is a pressing need for a highly sensitive method to analyze CTCs at the single-cell level. As an important branch of microfluidics, droplet microfluidics is a high-throughput and sensitive single-cell analysis platform for the quantitative detection and heterogeneity analysis of CTCs. In this review, we focus on the quantitative detection and heterogeneity analysis of CTCs using droplet microfluidics. Technologies that enable droplet microfluidics, particularly high-throughput droplet generation and high-efficiency droplet manipulation, are first discussed. Then, recent advances in detecting and analyzing CTCs using droplet microfluidics from the different aspects of nucleic acids, proteins, and metabolites are introduced. The purpose of this review is to provide guidance for the continued study of droplet microfluidics for CTC-based liquid biopsy.

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.

Flow lithography for structured microparticles: fundamentals, methods and applications

Structured microparticles, with unique shapes, customizable sizes, multiple materials, and spatially-defined chemistries, are leading the way for emerging 'lab on a particle' technologies. These microparticles with engineered designs find applications in multiplexed diagnostics, drug delivery, single-cell secretion assays, single-molecule detection assays, high throughput cytometry, micro-robotics, self-assembly, and tissue engineering. In this article we review state-of-the-art particle manufacturing technologies based on flow-assisted photolithography performed inside microfluidic channels. Important physicochemical concepts are discussed to provide a basis for understanding the fabrication technologies. These photolithography technologies are compared based on the structural as well as compositional complexity of the fabricated particles. Particles are categorized, from 1D to 3D particles, based on the number of dimensions that can be independently controlled during the fabrication process. After discussing the advantages of the individual techniques, important applications of the fabricated particles are reviewed. Lastly, a future perspective is provided with potential directions to improve the throughput of particle fabrication, realize new particle shapes, measure particles in an automated manner, and adopt the 'lab on a particle' technologies to other areas of research.

Hydrodynamics of Droplet Sorting in Asymmetric Acute Junctions

Droplet sorting is one of the fundamental manipulations of droplet-based microfluidics. Although many sorting methods have already been proposed, there is still a demand to develop new sorting methods for various applications of droplet-based microfluidics. This work presents numerical investigations on droplet sorting with asymmetric acute junctions. It is found that the asymmetric acute junctions could achieve volume-based sorting and velocity-based sorting. The pressure distributions in the asymmetric junctions are discussed to reveal the physical mechanism behind the droplet sorting. The dependence of the droplet sorting on the droplet volume, velocity, and junction angle is explored. The possibility of the employment of the proposed sorting method in most real experiments is also discussed. This work provides a new, simple, and cost-effective passive strategy to separate droplets in microfluidic channels. Moreover, the proposed acute junctions could be used in combination with other sorting methods, which may boost more opportunities to sort droplets.

Future foods: Design, fabrication and production through microfluidics

Many delicious foods are soft matter systems with health ingredients and unique internal structures that provide rich nutrition, unique textures, and popular flavors. Obtaining these special properties in food products usually requires specialized processes. Microfluidic technologies have been developed to physically manipulate liquids to produce a broad range of microunits, providing a suitable approach for precise fabrication of functional biomaterials with desirable interior structures in a bottom-up fashion. In this review, we present how microfluidics has been applied to produce gel-based structures and highlight their use in fabricating novel foods, focusing on, among others, cultured meat as a rapidly growing field in food industry. We first discuss the behaviors of food liquids in microchannels for fluidic structure design. Then, different types of microsized building blocks with specific geometries fabricated through microfluidics are introduced, including particles (point), fibers (line), and sheets (plane). These well-defined units can encapsulate or interact with cells, forming microtissues to construct meat products with desirable architectures. After that, we review approaches to scale up microfluidic devices for mass production of the hydrogel building blocks and highlight the challenges associated with bottom-up food production.

A novel hardmask-to-substrate pattern transfer method for creating 3D, multi-level, hierarchical, high aspect-ratio structures for applications in microfluidics and cooling technologies

This letter solves a major hurdle that mars photolithography-based fabrication of micro-mesoscale structures in silicon. Conventional photolithography is usually performed on smooth, flat wafer surfaces to lay a 2D design and subsequently etch it to create single-level features. It is, however, unable to process non-flat surfaces or already etched wafers and create more than one level in the structure. In this study, we have described a novel cleanroom-based process flow that allows for easy creation of such multi-level, hierarchical 3D structures in a substrate. This is achieved by introducing an ultra-thin sacrificial silicon dioxide hardmask layer on the substrate which is first 3D patterned via multiple rounds of lithography. This 3D pattern is then scaled vertically by a factor of 200–300 and transferred to the substrate underneath via a single shot deep etching step. The proposed method is also easily characterizable—using features of different topographies and dimensions, the etch rates and selectivities were quantified; this characterization information was later used while fabricating specific target structures. Furthermore, this study comprehensively compares the novel pattern transfer technique to already existing methods of creating multi-level structures, like grayscale lithography and chip stacking. The proposed process was found to be cheaper, faster, and easier to standardize compared to other methods—this made the overall process more reliable and repeatable. We hope it will encourage more research into hybrid structures that hold the key to dramatic performance improvements in several micro-mesoscale devices.

Artificial intelligence-powered microfluidics for nanomedicine and materials synthesis

Artificial intelligence (AI) is an emerging technology with great potential, and its robust calculation and analysis capabilities are unmatched by traditional calculation tools. With the promotion of deep learning and open-source platforms, the threshold of AI has also become lower. Combining artificial intelligence with traditional fields to create new fields of high research and application value has become a trend. AI has been involved in many disciplines, such as medicine, materials, energy, and economics. The development of AI requires the support of many kinds of data, and microfluidic systems can often mine object data on a large scale to support AI. Due to the excellent synergy between the two technologies, excellent research results have emerged in many fields. In this review, we briefly review AI and microfluidics and introduce some applications of their combination, mainly in nanomedicine and material synthesis. Finally, we discuss the development trend of the combination of the two technologies.