Controllable Fabrication of Inhomogeneous Microcapsules for Triggered Release by Osmotic Pressure

Synthesis of tunable thickness-to-diameter ratio microcapsules via a diffusion-controlled process for temperature-responsive release

Designing microcapsules with a complicated functionalized shell to respond to an external stimulus has attracted much attention for triggered release; however, simplifying the synthesis process remains a significant challenge. Herein, we initially propose a novel, simple synthesis strategy that utilizes a mixed solvent as the organic phase to control the diffusion of common monomers during interfacial polymerization, resulting in the successful preparation of microcapsules with tunable thickness-to-diameter ratios (T/D). The morphology of microcapsules is confirmed by scanning electron microscopy. We also observe that the T/D of the designed microcapsules progressively increases as the diffusion of monomers occurs, and the glass transition temperature of microcapsules is controlled. Furthermore, microcapsule-based crosslinking agents are applied to investigate the crosslinking reaction of poly(vinyl chloride). Rotational rheometer results indicate that the microcapsules exhibit an excellent external stimulus response, precisely triggering release at the predetermined temperature. This simple approach for the preparation of microcapsules with tunable physical properties has great potential for triggered release in diverse applications.

Tailoring Microemulsification Techniques for the Encapsulation of Diverse Cargo: A Systematic Analysis of Poly (Urea-Formaldehyde) Microcapsules

Cargo encapsulation through emulsion-based methods has been pondered over the years. Although several microemulsification techniques have been employed for the microcapsule's synthesis, there are still no clear guidelines regarding the suitability of one technique over the others or the impacts on the morphological and physicochemical stability of the final particles. Therefore, in this systematic study, we investigated the influence of synthesis parameters on the fabrication of emulsion-based microcapsules concerning morphological and physicochemical properties. Using poly(urea-formaldehyde) (PUF) microcapsules as a model system, and after determining the optimal core/shell ratio, we tested three different microemulsification techniques (magnetic stirring, ultrasonication, and mechanical stirring) and two different cargo types (100% TEGDMA (Triethylene glycol dimethacrylate) and 80% TEGDMA + 20% DMAM (N,N-Dimethylacrylamide)). The resulting microcapsules were characterized via optical and scanning electron microscopies, followed by size distribution analysis. The encapsulation efficiency was obtained through the extraction method, and the percentage reaction yield was calculated. Physicochemical properties were assessed by incubating the microcapsules under different osmotic pressures for 1 day and 1, 2, or 4 weeks. The data were analyzed statistically with one-way ANOVA and Tukey's tests (α = 0.05). Overall, the mechanical stirring resulted in the most homogeneous and stable microcapsules, with an increased reaction yield from 100% to 50% in comparison with ultrasonication and magnetic methods, respectively. The average microcapsule diameter ranged from 5 to 450 µm, with the smallest ones in the ultrasonication and the largest ones in the magnetic stirring groups. The water affinities of the encapsulated cargo influenced the microcapsule formation and stability, with the incorporation of DMAM leading to more homogeneous and stable microcapsules. Environmental osmotic pressure led to cargo loss or the selective swelling of the shells. In summary, this systematic investigation provides insights and highlights commonly overlooked factors that can influence microcapsule fabrication and guide the choice based on a diligent analysis of therapeutic niche requirements.

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.

Programmable Photoswitchable Microcapsules Enable Precise and Tailored Drug Delivery from Microfluidics

The development of precision personalized medicine poses a significant need for the next generation of advanced diagnostic and therapeutic technologies, and one of the key challenges is the development of highly time-, space-, and dose-controllable drug delivery systems that respond to the complex physiopathology of patient populations. In response to this challenge, an increasing number of stimuli-responsive smart materials are integrated into biomaterial systems for precise targeted drug delivery. Among them, responsive microcapsules prepared by droplet microfluidics have received much attention. In this study, we present a UV-visible light cycling mediated photoswitchable microcapsule (PMC) with dynamic permeability-switching capability for precise and tailored drug release. The PMCs were fabricated using a programmable pulsed aerodynamic printing (PPAP) technique, encapsulating an aqueous core containing magnetic nanoparticles and the drug doxorubicin (DOX) within a poly(lactic-co-glycolic acid) (PLGA) composite shell modified by PEG-b-PSPA. Selective irradiation of PMCs with ultraviolet (UV) or visible light (Vis) allows for high-precision time-, space-, and dose-controlled release of the therapeutic agent. An experimentally validated theoretical model was developed to describe the drug release pattern, holding promise for future customized programmable drug release applications. The therapeutic efficacy and value of patternable cancer cell treatment activated by UV radiation is demonstrated by our experimental results. After in vitro transcatheter arterial chemoembolization (TACE), PMCs can be removed by external magnetic fields to mitigate potential side effects. Our findings demonstrate that PMCs have the potential to integrate embolization, on-demand drug delivery, magnetic actuation, and imaging properties, highlighting their immense potential for tailored drug delivery and embolic therapy.

A portable microfluidic device for thermally controlled granular sample manipulation

Effective granular sample manipulation with a portable and visualizable microfluidic device is significant for lots of applications, such as point-of-care testing and cargo delivery. Herein, we report a portable microfluidic device for controlled particle focusing, migration and double-emulsion droplet release via thermal fields. The device mainly contains a microfluidic chip, a microcontroller with a DC voltage control unit, a built-in microscope with a video transmission unit and a smartphone. Five microheaters located at the bottom of the microfluidic chip are used to unevenly heat fluids and then induce thermal buoyancy flow and a thermocapillary effect, and the experiments can be conveniently visualized through a smartphone, which provides convenient sample detection in outdoor environments. To demonstrate the feasibility and multifunctionality of this device, the focusing manipulation of multiple particles is first analyzed by using silica particles and yeast cells as experimental samples. We can directly observe the particle focusing states on the screen of a smartphone, and the particle focusing efficiency can be flexibly tuned by changing the control voltage of the microheater. Then the study focus is transferred to single-particle migration. By changing the voltage combinations applied on four strip microheaters, the single particle can migrate at predetermined trajectory and speed, showing attractiveness for those applications needing sample transportation. Finally, we manipulate the special three-phase flow system of double-emulsion drops in thermal fields. Under the combined effect of the thermocapillary effect and increased instability, the shell of double-emulsion droplets gradually thins and finally breaks, resulting in the release of samples in inner cores. The core release speed can also be flexibly adjusted by changing the control voltage of the microheater. These three experiments successfully demonstrate the effectiveness and multifunctionality of this thermally actuated microfluidic device on granular manipulation. Therefore, this portable microfluidic device will be promising for lots of applications, such as analytical detection, microrobot actuation and cargo release.

Amphiphilicity-Driven Small Alcohols Regulate the Flexibility of Pesticide-Loaded Microcapsules for Better Foliar Adhesion and Utilization

The foliar loss of pesticides causes serious utilization decline and environmental risk. On the basis of biomimetics, pesticide-loaded microcapsules (MCs) with spontaneous deformation on foliar micro/nanostructures, like the snail suction cup, are prepared by interfacial polymerization. By controlling the usage or types of small alcohols in the MC preparation system, the flexibility of MCs is tunable. Through the investigation of emulsions and MC structures, we discover that the migration and distribution of small alcohols driven by amphiphilicity affect the process of interfacial polymerization between polyethylene glycol and 4,4-methylenediphenyl diisocyanate. By hydrophobic modification of the polymer and competition for oil monomers of small alcohols, the thickness and compactness of shells are reduced, whereas the density of the core is increased. As a result of the regulation in structures, the flexibility of MCs is improved significantly. In particularly, the MCs-N-pentanol (0.1 mol kg^-1) with the best flexibility show strong scouring resistance on varied foliar structures, sustained release property on the air/solid interface, and persistent control effect against foliar diseases. The pesticide-loaded soft MCs provide an effective way to improve pesticide foliar utilization.

Fabrication and characterization of core-shell microparticles containing an aqueous core

Core-shell microparticles containing an aqueous core have demonstrated their value for microencapsulation and drug delivery systems. The most important step in generating these uniquely structured microparticles is the formation of droplets and double emulsion. The droplet generator must meet the performance and reliability requirements, including accurate size control with tunability and monodispersity. Herein, we present a facile technique to generate surfactant-free core-shell droplets with an aqueous core in a microfluidic device. We demonstrate that the geometry of the core-shell droplets can be precisely adjusted by the flow rates of the droplet components. As the shell is polymerized after the formation of the core-shell droplets, the resulting solid microparticles ensure the encapsulation of the aqueous core and prevent undesired release. We then study experimentally and theoretically the behaviour of resultant microparticles under heating and compression. The microparticles demonstrate excellent stability under both thermal and mechanical loads. We show that the rupture force can be quantitatively predicted from the shell thickness relative to the outer shell radius. Experimental results and theoretical predictions confirm that the rupture force scales directly with the shell thickness.

Recent Advances in Drug Delivery System Fabricated by Microfluidics for Disease Therapy

Traditional drug therapy faces challenges such as drug distribution throughout the body, rapid degradation and excretion, and extensive adverse reactions. In contrast, micro/nanoparticles can controllably deliver drugs to target sites to improve drug efficacy. Unlike traditional large-scale synthetic systems, microfluidics allows manipulation of fluids at the microscale and shows great potential in drug delivery and precision medicine. Well-designed microfluidic devices have been used to fabricate multifunctional drug carriers using stimuli-responsive materials. In this review, we first introduce the selection of materials and processing techniques for microfluidic devices. Then, various well-designed microfluidic chips are shown for the fabrication of multifunctional micro/nanoparticles as drug delivery vehicles. Finally, we describe the interaction of drugs with lymphatic vessels that are neglected in organs-on-chips. Overall, the accelerated development of microfluidics holds great potential for the clinical translation of micro/nanoparticle drug delivery systems for disease treatment.

Recent advances in the microfluidic production of functional microcapsules by multiple-emulsion templating

Multiple-emulsion drops serve as versatile templates to design functional microcapsules due to their core-shell geometry and multiple compartments. Microfluidics has been used for the elaborate production of multiple-emulsion drops with a controlled composition, order, and dimensions, elevating the value of multiple-emulsion templates. Moreover, recent advances in the microfluidic control of the emulsification and parallelization of drop-making junctions significantly enhance the production throughput for practical use. Metastable multiple-emulsion drops are converted into stable microcapsules through the solidification of selected phases, among which solid shells are designed to function in a programmed manner. Functional microcapsules are used for the storage and release of active materials as drug carriers. Beyond their conventional uses, microcapsules can serve as microcompartments responsible for transmembrane communication, which is promising for their application in advanced microreactors, artificial cells, and microsensors. Given that post-processing provides additional control over the composition and construction of multiple-emulsion drops, they are excellent confining geometries to study the self-assembly of colloids and liquid crystals and produce miniaturized photonic devices. This review article presents the recent progress and current state of the art in the microfluidic production of multiple-emulsion drops, functionalization of solid shells, and applications of microcapsules.

Ultrasound-Responsive Aqueous Two-Phase Microcapsules for On-Demand Drug Release

Traditional implanted drug delivery systems cannot easily change their release profile in real time to respond to physiological changes. Here we present a microfluidic aqueous two-phase system to generate microcapsules that can release drugs on demand as triggered by focused ultrasound (FUS). The biphasic microcapsules are made of hydrogels with an outer phase of mixed molecular weight (MW) poly(ethylene glycol) diacrylate that mitigates premature payload release and an inner phase of high MW dextran with payload that breaks down in response to FUS. Compound release from microcapsules could be triggered as desired; 0.4 μg of payload was released across 16 on-demand steps over days. We detected broadband acoustic signals amidst low heating, suggesting inertial cavitation as a key mechanism for payload release. Overall, FUS-responsive microcapsules are a biocompatible and wirelessly triggerable structure for on-demand drug delivery over days to weeks.

Deformation and rupture of microcapsules flowing through constricted capillary

The dynamics of deformable microcapsules flowing through constricted channels is relevant in target delivery of chemicals in physiological systems, porous media, microfluidic medical diagnostic devices and many other applications. In some situations, the microcapsules need to sustain the stress they are subjected to as they flow through constricted channels and in others, the stress may be the rupture trigger used to release the internal content. We experimentally investigate the flow of monodispersed gellan gum microcapsules through a constricted capillary tube by measuring the evolution of the pressure difference and flow visualization. The maximum pressure difference and capsule deformation is obtained for capsules with different diameter and shell thickness. We map the conditions, e.g. diameter and shell thickness, at which the capsule membrane ruptures during the flow, releasing its internal phase.

Sporopollenin Exine Microcapsules as Potential Intestinal Delivery System of Probiotics

Despite several decades of research into encapsulation of bacteria, most of the proposed technologies are in the form of immobilized cultures. In this work, sporopollenin exine capsules (SECs) opened, using silica particles which act as pressing micro-probes, and loaded with Lactobacillus casei (L. casei) cells, are described for the first time. The proposed encapsulation provided ≈30× higher encapsulation yield (30.87%), compared to direct compression of SECs (0.99%). Encapsulated L. casei cells show 1.21- and 2.25-folds higher viability compared to free cells, in in vitro simulated fasted and fed media representing the human gastrointestinal (GI) tract, respectively. Encapsulated L. casei can proliferate inside the SECs, generating enough pressure to cause the SECs to burst and release the viable and metabolically active cells. The noticeable difference with the application of the SECs as a means of encapsulation is that the SECs may act as a bioreactor and provide time for the encapsulated cells to multiply thousands of times before being released, following the SEC's burst. The unique advantages of SECs alongside the proposed encapsulation method, demonstrates the potential application of SECs as delivery system of probiotics to the distal part of the human GI tract.

Microfluidic Fabrication of Phase-Inverted Microcapsules with Asymmetric Shell Membranes with Graded Porosity

Microcapsules with liquid cores and solid shells are attractive as dispersible protective micron-sized containers. Applications that rely on molecular mass transport often require a combination of size selectivity, high permeability, and mechanical stability. Capsule architectures that combine all these features represent a material property, design, and fabrication challenge. In this work, the design of an asymmetric microcapsule shell architecture is reported to achieve a good combination of the desired features. Poly(methyl methacrylate) phase-inverted microcapsules featuring an asymmetric graded macroporous shell covered with a dense skin separation layer are obtained from water-in-oil-in-water double emulsion drops that are phase-inverted in a water-based coagulation bath. The phase-inverted microcapsules exhibit good mechanical stability and allow for high permeability of its shell membrane with molecular size dependence.

Fabrication of syntactic foam fillers via manipulation of on-chip quasi concentric nanoparticle-shelled droplet templates

Syntactic foams with fly ash cenospheres or commercial microballoons as fillers have been widely used in various applications ranging from aerospace to marine fields and the automotive industry. However, these two extensively adopted fillers possess multiple shortcomings, such as variations in the composition, material degeneration and distinct structural heterogeneity, which will inevitably hamper accurate prediction of the structure-property relationship and the corresponding design of the syntactic foams, reducing material utilization. Here, we present a microfluidic-based approach integrated with a subsequent heat treatment process to engineer syntactic foam fillers with a predefined composition, specified dimensional scope and reduced structural heterogeneity. These fillers are fully guaranteed by the synergy of the flexible and controllable generation of droplet templates with hydrodynamic regulation and rational selection of the nanoparticle dynamic response with respect to the heating temperature. In addition, two distinct surface morphologies have been observed with a temperature demarcation point of 1473 K, further endowing the fillers with multiplicity and optionality, simultaneously laying the foundation to regulate the properties of the syntactic foams through the diversity of the filler selection. Then, we fabricated a syntactic foam specimen by mold casting, and the integrity of the fillers inside was verified using an elaborate buoyancy comparison experiment, exhibiting its potential value in lightweight related applications. As the fillers derived from our approach show significant advantages over conventional ones, they will provide considerable benefits for the regulation and improvement of syntactic foam fillers in many practical applications.