Gas Slug Microfluidics: A Unique Tool for Ultrafast, Highly Controlled Growth of Iron Oxide Nanostructures

Microwave-Assisted Silanization of Magnetite Nanoparticles Pre-Synthesized by a 3D Microfluidic Platform

Magnetite nanoparticles (Fe3O4 NPs) are among the most investigated nanomaterials, being recognized for their biocompatibility, versatility, and strong magnetic properties. Given that their applicability depends on their dimensions, crystal morphology, and surface chemistry, Fe3O4 NPs must be synthesized in a controlled, simple, and reproducible manner. Since conventional methods often lack tight control over reaction parameters and produce materials with unreliable characteristics, increased scientific interest has been directed to microfluidic techniques. In this context, the present paper describes the development of an innovative 3D microfluidic platform suitable for synthesizing uniform Fe3O4 NPs with fine-tuned properties. On-chip co-precipitation was performed, followed by microwave-assisted silanization. The obtained nanoparticles were characterized from the compositional and microstructural perspectives by X-ray diffraction (XRD) and transmission electron microscopy (TEM). Moreover, supplementary physicochemical investigations, such as Fourier Transform Infrared Spectroscopy (FT-IR), Kaiser Test, Ultraviolet-Visible (UV-Vis) Spectrophotometry, Dynamic Light Scattering (DLS), and Thermogravimetry and Differential Scanning Calorimetry (TG-DSC) analyses, demonstrated the successful surface modification. Considering the positive results, the presented synthesis and functionalization method represents a fast, reliable, and effective alternative for producing tailored magnetic nanoparticles.

Biocatalysis as a Green Approach for Synthesis of Iron Nanoparticles—Batch and Microflow Process Comparison

There is a growing need for production of iron particles due to their possible use in numerous systems (e.g., electrical, magnetic, catalytic, biological and others). Although severe reaction conditions and heavy solvents are frequently used in production of nanoparticles, green synthesis has arisen as an eco-friendly method that uses biological catalysts. Various precursors are combined with biological material (such as enzymes, herbal extracts, biomass, bacteria or yeasts) that contain chemicals from the main or secondary metabolism that can function as catalysts for production of nanoparticles. In this work, batch (“one-pot”) biosynthesis of iron nanoparticles is reviewed, as well as the possibilities of using microfluidic systems for continuous biosynthesis of iron nanoparticles, which could overcome the limitations of batch synthesis.

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.

Microfluidic Synthesis of -NH2- and -COOH-Functionalized Magnetite Nanoparticles

Microfluidics has emerged as a promising alternative for the synthesis of nanoparticles, which ensures precise control over the synthesis parameters, high uniformity, reproducibility, and ease of integration. Therefore, the present study investigated a one-step synthesis and functionalization of magnetite nanoparticles (MNPs) using sulfanilic acid (SA) and 4-sulfobenzoic acid (SBA). The flows of both the precursor and precipitating/functionalization solutions were varied in order to ensure the optimal parameters. The obtained nanoparticles were characterized through dynamic light scattering (DLS) and zeta potential, X-ray diffraction (XRD), selected area electron diffraction (SAED), transmission electron microscopy (TEM) and high-resolution TEM (HR-TEM), Fourier transform infrared spectroscopy (FT-IR), thermogravimetry and differential scanning calorimetry (TG-DSC), and vibrating sample magnetometry (VSM). The results demonstrated the successful synthesis of magnetite as the unique mineralogical phase, as well as the functionalization of the nanoparticles. Furthermore, the possibility to control the crystallinity, size, shape, and functionalization degree by varying the synthesis parameters was further confirmed. In this manner, this study validated the potential of the microfluidic platform to develop functionalized MNPs, which are suitable for biomedical and pharmaceutical applications.

Microfluidic Nanoparticles for Drug Delivery

Nanoparticles (NPs) have attracted tremendous interest in drug delivery in the past decades. Microfluidics offers a promising strategy for making NPs for drug delivery due to its capability in precisely controlling NP properties. The recent success of mRNA vaccines using microfluidics represents a big milestone for microfluidic NPs for pharmaceutical applications, and its rapid scaling up demonstrates the feasibility of using microfluidics for industrial-scale manufacturing. This article provides a critical review of recent progress in microfluidic NPs for drug delivery. First, the synthesis of organic NPs using microfluidics focusing on typical microfluidic methods and their applications in making popular and clinically relevant NPs, such as liposomes, lipid NPs, and polymer NPs, as well as their synthesis mechanisms are summarized. Then, the microfluidic synthesis of several representative inorganic NPs (e.g., silica, metal, metal oxide, and quantum dots), and hybrid NPs is discussed. Lastly, the applications of microfluidic NPs for various drug delivery applications are presented.

Revealing the crystal phases of primary particles formed during the coprecipitation of iron oxides

The mechanistic investigation of the coprecipitation formation of iron oxides has been a long-standing challenge due to the rapid reaction kinetics and high complexity of iron hydrolysis reactions. Although a few studies have suggested that the coprecipitation of iron oxide nanoparticles follows a non-classic route through inter-particle attachment, the compositions of the primary particles remain undetermined. Herein, by using a specially designed gas/liquid mixed phase fluidic reactor we controlled the reaction time from 3 s to over 5 min, and successfully identified the concentration of different intermediate phases as a function of time. We suggest that the initial Fe³⁺ ions are hydrolyzed under the alkaline condition to give Fe(OH)₃, which then rapidly dehydrates to yield α-FeOOH. In the presence of Fe²⁺ ions, which could also act as the catalyst, α-FeOOH finally transforms to Fe₃O₄.

Ferrofluids and bio-ferrofluids: looking back and stepping forward

Ferrofluids investigated along for about five decades are ultrastable colloidal suspensions of magnetic nanoparticles, which manifest simultaneously fluid and magnetic properties. Their magnetically controllable and tunable feature proved to be from the beginning an extremely fertile ground for a wide range of engineering applications. More recently, biocompatible ferrofluids attracted huge interest and produced a considerable increase of the applicative potential in nanomedicine, biotechnology and environmental protection. This paper offers a brief overview of the most relevant early results and a comprehensive description of recent achievements in ferrofluid synthesis, advanced characterization, as well as the governing equations of ferrohydrodynamics, the most important interfacial phenomena and the flow properties. Finally, it provides an overview of recent advances in tunable and adaptive multifunctional materials derived from ferrofluids and a detailed presentation of the recent progress of applications in the field of sensors and actuators, ferrofluid-driven assembly and manipulation, droplet technology, including droplet generation and control, mechanical actuation, liquid computing and robotics.

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.

High Temperature Continuous Flow Syntheses of Iron Oxide Nanoflowers Using the Polyol Route in a Multi-Parametric Millifluidic Device

One of the most versatile routes for the elaboration of nanomaterials in materials science, including the synthesis of magnetic iron oxide nanoclusters, is the high-temperature polyol process. However, despite its versatility, this process still lacks reproducibility and scale-up, in addition to the low yield obtained in final materials. In this work, we demonstrate a home-made multiparametric continuous flow millifluidic system that can operate at high temperatures (up to 400 °C). After optimization, we validate its potential for the production of nanomaterials using the polyol route at 220 °C by elaborating ferrite iron oxide nanoclusters called nanoflowers (CoFe₂O₄, Fe₃O₄, MnFe₂O₄) with well-controlled nanostructure and composition, which are highly demanded due to their physical properties. Moreover, we demonstrate that by using such a continuous process, the chemical yield and reproducibility of the nanoflower synthesis are strongly improved as well as the possibility to produce these nanomaterials on a large scale with quantities up to 45 g per day.

Microfluidics Technology for the Design and Formulation of Nanomedicines

In conventional drug administration, drug molecules cross multiple biological barriers, distribute randomly in the tissues, and can release insufficient concentrations at the desired pathological site. Controlling the delivery of the molecules can increase the concentration of the drug in the desired location, leading to improved efficacy, and reducing the unwanted effects of the molecules under investigation. Nanoparticles (NPs), have shown a distinctive potential in targeting drugs due to their unique properties, such as large surface area and quantum properties. A variety of NPs have been used over the years for the encapsulation of different drugs and biologics, acting as drug carriers, including lipid-based and polymeric NPs. Applying NP platforms in medicines significantly improves the disease diagnosis and therapy. Several conventional methods have been used for the manufacturing of drug loaded NPs, with conventional manufacturing methods having several limitations, leading to multiple drawbacks, including NPs with large particle size and broad size distribution (high polydispersity index), besides the unreproducible formulation and high batch-to-batch variability. Therefore, new methods such as microfluidics (MFs) need to be investigated more thoroughly. MFs, is a novel manufacturing method that uses microchannels to produce a size-controlled and monodispersed NP formulation. In this review, different formulation methods of polymeric and lipid-based NPs will be discussed, emphasizing the different manufacturing methods and their advantages and limitations and how microfluidics has the capacity to overcome these limitations and improve the role of NPs as an effective drug delivery system.

Development of an in-line magnetometer for flow chemistry and its demonstration for magnetic nanoparticle synthesis

Despite the wide usage of magnetic nanoparticles, it remains challenging to synthesise particles with properties that exploit each application's full potential. Time consuming experimental procedures and particle analysis hinder process development, which is commonly constrained to a handful of experiments without considering particle formation kinetics, reproducibility and scalability. Flow reactors are known for their potential of large-scale production and high-throughput screening of process parameters. These advantages, however, have not been utilised for magnetic nanoparticle synthesis where particle characterisation is performed, with a few exceptions, post-synthesis. To overcome this bottleneck, we developed a highly sensitive magnetometer for flow reactors to characterise magnetic nanoparticles in solution in-line and in real-time using alternating current susceptometry. This flow magnetometer enriches the flow-chemistry toolbox by facilitating continuous quality control and high-throughput screening of magnetic nanoparticle syntheses. The sensitivity required to monitor magnetic nanoparticle syntheses at the typically low concentrations (<100 mM of Fe) was achieved by comparing the signals induced in the sample and reference cell, each of which contained near-identical pairs of induction and pick-up coils. The reference cell was filled only with air, whereas the sample cell was a flow cell allowing sample solution to pass through. Balancing the flow and reference cell impedance with a newly developed electronic circuit was pivotal for the magnetometer's sensitivity. To showcase its potential, the flow magnetometer was used to monitor two iron oxide nanoparticle syntheses with well-known particle formation kinetics, i.e., co-precipitation syntheses with sodium carbonate and sodium hydroxide as base, which have been previously studied via synchrotron X-ray diffraction. The flow magnetometer facilitated batch (on-line) and flow (in-line) synthesis monitoring, providing new insights into the particle formation kinetics as well as, effect of temperature and pH. The compact lab-scale flow device presented here, opens up new possibilities for magnetic nanoparticle synthesis and manufacturing, including 1) early stage reaction characterisation 2) process monitoring and control and 3) high-throughput screening in combination with flow reactors.

Magnetite nanoparticles: Synthesis methods - A comparative review

Iron oxide-based nanoparticles have gathered tremendous scientific interest towards their application in a variety of fields. Magnetite has been particularly investigated due to its readily availability, versatility, biocompatibility, biodegradability, and special magnetic properties. As the behavior of nano-scale magnetite is in direct relation to its shape, size, and surface chemistry, accurate control over the nanoparticle synthesis process is essential in obtaining quality products for the intended end uses. Several chemical, physical, and biological methods are found in the literature and implemented in the laboratory or industrial practice. However, non-conventional methods emerged in recent years to bring unprecedented synthesis performances in terms of better-controlled morphologies, sizes, and size distribution. Particularly, microfluidic methods represent a promising technology towards smaller reagent volume use, waste reduction, precise control of fluid mixing, and ease of automation, overcoming some of the major drawbacks of conventional bulk methods. This review aims to present the main properties, applications, and synthesis methods of magnetite, together with the newest advancements in this field.

Synthesis and applications of surface-modified magnetic nanoparticles: progress and future prospects

The growing use of magnetic nanoparticles (MNPs) demands cost-effective methods for their synthesis that allow proper control of particle size and size distribution. The unique properties of MNPs include high specific surface area, ease of functionalization, chemical stability and superparamagnetic behavior, with applications in catalysis, data and energy storage, environmental remediation and biomedicine. This review highlights breakthroughs in the use of MNPs since their initial introduction in biomedicine to the latest challenging applications; special attention is paid to the importance of proper coating and functionalization of the particle surface, which dictates the specific properties for each application. Starting from the first report following LaMer’s theory in 1950, this review discusses and analyzes methods of synthesizing MNPs, with an emphasis on functionality and applications. However, several hurdles, such as the design of reactors with suitable geometries, appropriate control of operating conditions and, in particular, reproducibility and scalability, continue to prevent many applications from reaching the market. The most recent strategy, the use of microfluidics to achieve continuous and controlled synthesis of MNPs, is therefore thoroughly analyzed. This review is the first to survey continuous microfluidic coating or functionalization of particles, including challenging properties and applications.

Accelerated Development of Colloidal Nanomaterials Enabled by Modular Microfluidic Reactors: Toward Autonomous Robotic Experimentation

In recent years, microfluidic technologies have emerged as a powerful approach for the advanced synthesis and rapid optimization of various solution-processed nanomaterials, including semiconductor quantum dots and nanoplatelets, and metal plasmonic and reticular framework nanoparticles. These fluidic systems offer access to previously unattainable measurements and synthesis conditions at unparalleled efficiencies and sampling rates. Despite these advantages, microfluidic systems have yet to be extensively adopted by the colloidal nanomaterial community. To help bridge the gap, this progress report details the basic principles of microfluidic reactor design and performance, as well as the current state of online diagnostics and autonomous robotic experimentation strategies, toward the size, shape, and composition-controlled synthesis of various colloidal nanomaterials. By discussing the application of fluidic platforms in recent high-priority colloidal nanomaterial studies and their potential for integration with rapidly emerging artificial intelligence-based decision-making strategies, this report seeks to encourage interdisciplinary collaborations between microfluidic reactor engineers and colloidal nanomaterial chemists. Full convergence of these two research efforts offers significantly expedited and enhanced nanomaterial discovery, optimization, and manufacturing.

Microfluidic Synthesis of Iron Oxide Nanoparticles

Research efforts into the production and application of iron oxide nanoparticles (IONPs) in recent decades have shown IONPs to be promising for a range of biomedical applications. Many synthesis techniques have been developed to produce high-quality IONPs that are safe for in vivo environments while also being able to perform useful biological functions. Among them, coprecipitation is the most commonly used method but has several limitations such as polydisperse IONPs, long synthesis times, and batch-to-batch variations. Recent efforts at addressing these limitations have led to the development of microfluidic devices that can make IONPs of much-improved quality. Here, we review recent advances in the development of microfluidic devices for the synthesis of IONPs by coprecipitation. We discuss the main architectures used in microfluidic device design and highlight the most prominent manufacturing methods and materials used to construct these microfluidic devices. Finally, we discuss the benefits that microfluidics can offer to the coprecipitation synthesis process including the ability to better control various synthesis parameters and produce IONPs with high production rates.

Highly Selective Oxidation of Organic Sulfides by a Conjugated Polymer as the Photosensitizer for Singlet Oxygen Generation

A cationic conjugated polyelectrolyte PPET3-N2 was used as a photosensitizer for photocatalytic oxidation of organic sulfides, including thioanisole, ethyl phenyl sulfide, 4-methylphenyl methyl sulfide, etc., to form sulfoxides with good yields and high selectivity. Oxidation reactions were performed in both batch and microfluidic reactors, where the microfluidic reactor can significantly promote the conversion of photocatalytic oxidation reaction to over 98% in about 8 min. Further studies of the photocatalytic oxidation of the antitumor drug ricobendazole in the microfluidic reactor demonstrate the potential application of the polymer material in organic reactions given its high selectivity, good efficiency, and operation convenience.

Rapid Millifluidic Synthesis of Stable High Magnetic Moment FexCy Nanoparticles for Hyperthermia

A millifluidic reactor with a 0.76 mm internal diameter was utilized for the synthesis of monodisperse, high magnetic moment, iron carbide (FexCy) nanoparticles by thermal decomposition of iron pentacarbonyl (Fe(CO)5) in 1-octadecene in the presence of oleylamine at 22 min nominal residence time. The effect of reaction conditions (temperature and pressure) on the size, morphology, crystal structure, and magnetic properties of the nanoparticles was investigated. The system developed facilitated the thermal decomposition of precursor at reaction conditions (up to 265 °C and 4 bar) that cannot be easily achieved in conventional batch reactors. The degree of carbidization was enhanced by operating at elevated temperature and pressure. The nanoparticles synthesized in the flow reactor had size 9-18 nm and demonstrated high saturation magnetization (up to 164 emu/gFe). They further showed good stability against oxidation after 2 months of exposure in air, retaining good saturation magnetization values with a change of no more than 10% of the initial value. The heating ability of the nanoparticles in an alternating magnetic field was comparable with other ferrites reported in the literature, having intrinsic loss power values up to 1.52 nHm2 kg-1.

Continuous Synthesis of Nanocrystals via Flow Chemistry Technology

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

A Modular Millifluidic Platform for the Synthesis of Iron Oxide Nanoparticles with Control over Dissolved Gas and Flow Configuration

Gas-liquid reactions are poorly explored in the context of nanomaterials synthesis, despite evidence of significant effects of dissolved gas on nanoparticle properties. This applies to the aqueous synthesis of iron oxide nanoparticles, where gaseous reactants can influence reaction rate, particle size and crystal structure. Conventional batch reactors offer poor control of gas-liquid mass transfer due to lack of control on the gas-liquid interface and are often unsafe when used at high pressure. This work describes the design of a modular flow platform for the water-based synthesis of iron oxide nanoparticles through the oxidative hydrolysis of Fe2+ salts, targeting magnetic hyperthermia applications. Four different reactor systems were designed through the assembly of two modular units, allowing control over the type of gas dissolved in the solution, as well as the flow pattern within the reactor (single-phase and liquid-liquid two-phase flow). The two modular units consisted of a coiled millireactor and a tube-in-tube gas-liquid contactor. The straightforward pressurization of the system allows control over the concentration of gas dissolved in the reactive solution and the ability to operate the reactor at a temperature above the solvent boiling point. The variables controlled in the flow system (temperature, flow pattern and dissolved gaseous reactants) allowed full conversion of the iron precursor to magnetite/maghemite nanocrystals in just 3 min, as compared to several hours normally employed in batch. The single-phase configuration of the flow platform allowed the synthesis of particles with sizes between 26.5 nm (in the presence of carbon monoxide) and 34 nm. On the other hand, the liquid-liquid two-phase flow reactor showed possible evidence of interfacial absorption, leading to particles with different morphology compared to their batch counterpart. When exposed to an alternating magnetic field, the particles produced by the four flow systems showed ILP (intrinsic loss parameter) values between 1.2 and 2.7 nHm2/kg. Scale up by a factor of 5 of one of the configurations was also demonstrated. The scaled-up system led to the synthesis of nanoparticles of equivalent quality to those produced with the small-scale reactor system. The equivalence between the two systems is supported by a simple analysis of the transport phenomena in the small and large-scale setups.

Frequency dependent multiphase flows on centrifugal microfluidics

The simultaneous flow of gas and liquids in large scale conduits is an established approach to enhance the performance of different working systems under critical conditions. On the microscale, the use of gas-liquid flows is challenging due to the dominance of surface tension forces. Here, we present a technique to generate common gas-liquid flows on a centrifugal microfluidic platform. It consists of a spiral microchannel and specific micro features that allow for temporal and local control of stratified and slug flow regimes. We investigate several critical parameters that induce different gas-liquid flows and cause the transition between stratified and slug flows. We have analytically derived formulations that are compared with our experimental results to deliver a general guideline for designing specific gas-liquid flows. As an application of the gas-liquid flows in enhancing microfluidic systems' performance, we show the acceleration of the cell growth of E. coli bacteria in comparison to traditional culturing methods.

Continuous Multistage Synthesis and Functionalization of Sub-100 nm Silica Nanoparticles in 3D-Printed Continuous Stirred-Tank Reactor Cascades

The controlled and continuous production of nanoparticles (NPs) with functionalized surfaces remains a technological challenge. We present a multistage synthetic platform, consisting of 3D-printed miniature continuous stirred-tank reactor (CSTR) cascades, for the continuous synthesis and functionalization of SiO₂ NPs. The use of the CSTR platform provides ideal and rapid mixing of precursor solutions, precise injection of additional reagents for multistep reactions, and facile operation when using viscous solutions and handling of syntheses with longer reaction times. To exemplify the use of such custom-designed CSTR cascades, amine- and carbohydrate-functionalized SiO₂ NPs are chosen as model reaction systems. In particular, the intensified flow reactor units allowed for the reproducible formation of SiO₂ NPs with diameters less than 100 nm and narrow size distributions (3-8%). Most importantly, by assembling various 3D-printed CSTR cascades, we synthesized gluconolactone-capped polyethylenimine-modified silica NPs in a fully continuous manner. The inherent control over NP surface charge, reactor scalability, and the significant shortening of processing times (less than 10 min) compared to batch methodologies (several days) strongly indicate the ability of the reactor technology to accelerate continuous nanomanufacturing. In general, it provides a simple route for the reproducible preparation of functionalized NPs, thus expanding the gamut of flow reactors for material synthesis.

Parallel multiphase nanofluidics utilizing nanochannels with partial hydrophobic surface modification and application to femtoliter solvent extraction

In the field of microfluidics, utilizing parallel multiphase flows with immiscible liquid/liquid or gas/liquid interfaces along a microchannel has achieved the integration of various chemical processes for analyses and syntheses. Recently, our group has developed nanofluidics that exploits 100 nm nanochannels to realize ultra-small (aL to fL scale) and highly efficient chemical operations. Novel applications such as single-molecule analyses and single-cell omics are anticipated. However, the formation of parallel multiphase flows in a nanochannel remains challenging. To this end, here we developed a novel method for nanoscale partial hydrophobic surface modification of a nanochannel utilizing a focused ion beam. Hydrophobic and hydrophilic areas could be patterned beside one another even in a 60 nm glass nanochannel. Because this patterning maintained the liquid/liquid interface in the nanochannel based on the difference in wettability, stable aqueous/organic parallel two-phase flow in a 40 fL nanochannel was realized for the first time. Utilizing this flow, nanoscale unit operations involving phase confluence, extraction and phase separation were integrated to demonstrate solvent extraction of a lipid according to the Bligh-Dyer method, which is a broadly used pretreatment process in lipidomics. We accomplished the separation of a lipid and an amino acid in a sample volume of 4 fL (250 times smaller than the pL volume of a single cell) with a processing time of 1 ms (10 000 times faster than that in a microchannel). This study therefore provides a technological breakthrough that advances the field of nanofluidics to allow multiphase chemical processing at fL volumes.

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.

Continuous Microfluidic Synthesis of Pd Nanocubes and PdPt Core-Shell Nanoparticles and Their Catalysis of NO2 Reduction

Faceted colloidal nanoparticles are currently of immense interest due to their unique electronic, optical, and catalytic properties. However, continuous flow synthesis that enables rapid formation of faceted nanoparticles of single or multi-elemental composition is not trivial. We present a continuous flow synthesis route for the synthesis of uniformly sized Pd nanocubes and PdPt core-shell nanoparticles in a single-phase microfluidic reactor, which enables rapid formation of shaped nanoparticles with a reaction time of 3 min. The PdPt core-shell nanoparticles feature a dendritic, high surface area with the Pt shell covering the Pd core, as verified using high-resolution scanning transmission electron microscopy and energy dispersive X-ray spectroscopy. The Pd nanocubes and PdPt core-shell particles are catalytically tested during NO₂ reduction in the presence of H₂ in a flow pocket reactor. The Pd nanocubes exhibited low-temperature activity (i.e., <136 °C) and poor selectivity performance toward production of N₂O or N₂, whereas PdPt core-shell nanoparticles showed higher activity and were found to achieve better selectivity during NO₂ reduction retaining its basic structure at relatively elevated temperatures, making the PdPt core-shell particles a unique, desirable synergic catalyst material for potential use in NO_x abatement processes.

Superstructure of a Metal-Organic Framework Derived from Microdroplet Flow Reaction: An Intermediate State of Crystallization by Particle Attachment

Understanding the crystallization pathway is of fundamental importance in controlling structures and functionalities for metal-organic frameworks (MOFs), but only few studies have been reported on the mechanism of crystallization for MOFs to date. Here, by using a microdroplet flow (MF) reaction technique, we successfully revealed the different status of HKUST-1 during its crystal growth process. The morphologies and structures of crystals at different stages were recorded and characterized by scanning electron microscopy, transmission electron microscopy, and small-angle X-ray diffraction. Experimental observations clearly demonstrate a process of crystallization by particle attachment (CPA) for crystal growth of HKUST-1 under MF conditions. The superstructure of HKUST-1, which is assembled from oriented attachment of nanosized particles of HKUST-1, is observed at early stage of crystal growth. This type of superstructure gradually transforms to true single crystals through a ripening effect upon increasing residence time, accompanied by increase in dimensions of crystals. Thus, the superstructure is the intermediate state during crystallization and acts as the bridge between disordered reactants and highly ordered single crystals. Based on these findings, the crystal growth of HKUST-1 in MF reaction can be elucidated as a process involving three steps: the generation of nanosized primary particles, the following assembly of the primary particles into a superstructure, and the ripening of superstructure into a crystal. Furthermore, the superstructure of HKUST-1 shows superior performance for CO₂ and CH₄ adsorptions. The CPA mechanism in the crystallization of HKUST-1 demonstrated in this work is in clear contrast to the monomer-by-monomer addition mechanism in classic models of crystal growth. This mechanism could have important reference meaning for understanding the crystal growth mechanism of other type of MOFs or other special morphologies.

Continuous flow chemistry: where are we now? Recent applications, challenges and limitations

A general outlook of the changing face of chemical synthesis is provided in this article through recent applications of continuous flow processing in both industry and academia. The benefits, major challenges and limitations associated with the use of this mode of processing are also given due attention as an attempt to put into perspective the current position of continuous flow processing, either as an alternative or potential combinatory technology for batch processing.

Transport of a Micro Liquid Plug in a Gas-Phase Flow in a Microchannel

Micro liquid droplets and plugs in the gas-phase in microchannels have been utilized in microfluidics for chemical analysis and synthesis. While higher velocities of droplets and plugs are expected to enable chemical processing at higher efficiency and higher throughput, we recently reported that there is a limit of the liquid plug velocity owing to splitting caused by unstable wetting to the channel wall. This study expands our experimental work to examine the dynamics of a micro liquid plug in the gas phase in a microchannel. The motion of a single liquid plug, 0.4⁻58 nL in volume, with precise size control in 39- to 116-m-diameter hydrophobic microchannels was investigated. The maximum velocity of the liquid plug was 1.5 m/s, and increased to 5 m/s with splitting. The plug velocity was 20% of that calculated using the Hagen-Poiseuille equation. It was found that the liquid plug starts splitting when the inertial force exerted by the fluid overcomes the surface tension, i.e., the Weber number (ratio of the inertial force to the surface tension) is higher than 1. The results can be applied in the design of microfluidic devices for various applications that utilize liquid droplets and plugs in the gas phase.

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.

Nanoengineering a library of metallic nanostructures using a single microfluidic reactor

Microfluidic synthesis in a microfabricated reactor enables fast and facile synthesis of a wide library of metallic nanostructures: monometallic, bimetallic, anisotropic growth and heterostructures. Specific nanostructures are realized by selection of flow pattern and synthesis parameters. The technique is shown to have advantages over conventional batch technologies. Not only does it allow faster scalable synthesis, but also realization of nanostructures hitherto not reported such as Pt-Ru, Pt-Ni and Pt-Co nanodendrites, Pt-Pd heterostructures, Ag-Pd core-shell NPs, Au-Pd nanodumbbells and Au-Pd nanosheets.

Shape-controlled continuous synthesis of metal nanostructures

A segmented flow-based microreactor is used for the continuous production of faceted nanocrystals. Flow segmentation is proposed as a versatile tool to manipulate the reduction kinetics and control the growth of faceted nanostructures; tuning the size and shape. Switching the gas from oxygen to carbon monoxide permits the adjustment in nanostructure growth from 1D (nanorods) to 2D (nanosheets). CO is a key factor in the formation of Pd nanosheets and Pt nanocubes; operating as a second phase, a reductant, and a capping agent. This combination confines the growth to specific structures. In addition, the segmented flow microfluidic reactor inherently has the ability to operate in a reproducible manner at elevated temperatures and pressures whilst confining potentially toxic reactants, such as CO, in nanoliter slugs. This continuous system successfully synthesised Pd nanorods with an aspect ratio of 6; thin palladium nanosheets with a thickness of 1.5 nm; and Pt nanocubes with a 5.6 nm edge length, all in a synthesis time as low as 150 s.

Feroxyhyte nanoflakes coupled to up-converting carbon nanodots: a highly active, magnetically recoverable, Fenton-like photocatalyst in the visible-NIR range

Magnetic traffic-lights for photocatalysis: a novel nanohybrid combining feroxyhyte nanoflakes and upconverting carbon nanolights extends the activity range towards the near-infrared using inexpensive LED illumination.