High-volume production of single and compound emulsions in a microfluidic parallelization arrangement coupled with coaxial annular world-to-chip interfaces

Microfluidic Biochips for Single-Cell Isolation and Single-Cell Analysis of Multiomics and Exosomes

Single-cell multiomic and exosome analyses are potent tools in various fields, such as cancer research, immunology, neuroscience, microbiology, and drug development. They facilitate the in-depth exploration of biological systems, providing insights into disease mechanisms and aiding in treatment. Single-cell isolation, which is crucial for single-cell analysis, ensures reliable cell isolation and quality control for further downstream analyses. Microfluidic chips are small lightweight systems that facilitate efficient and high-throughput single-cell isolation and real-time single-cell analysis on- or off-chip. Therefore, most current single-cell isolation and analysis technologies are based on the single-cell microfluidic technology. This review offers comprehensive guidance to researchers across different fields on the selection of appropriate microfluidic chip technologies for single-cell isolation and analysis. This review describes the design principles, separation mechanisms, chip characteristics, and cellular effects of various microfluidic chips available for single-cell isolation. Moreover, this review highlights the implications of using this technology for subsequent analyses, including single-cell multiomic and exosome analyses. Finally, the current challenges and future prospects of microfluidic chip technology are outlined for multiplex single-cell isolation and multiomic and exosome analyses.

High-Throughput Single-Cell, Single-Mitochondrial DNA Assay Using Hydrogel Droplet Microfluidics

There is growing interest in understanding the biological implications of single cell heterogeneity and heteroplasmy of mitochondrial DNA (mtDNA), but current methodologies for single-cell mtDNA analysis limit the scale of analysis to small cell populations. Although droplet microfluidics have increased the throughput of single-cell genomic, RNA, and protein analysis, their application to sub-cellular organelle analysis has remained a largely unsolved challenge. Here, we introduce an agarose-based droplet microfluidic approach for single-cell, single-mtDNA analysis, which allows simultaneous processing of hundreds of individual mtDNA molecules within >10,000 individual cells. Our microfluidic chip encapsulates individual cells in agarose beads, designed to have a sufficiently dense hydrogel network to retain mtDNA after lysis and provide a robust scaffold for subsequent multi-step processing and analysis. To mitigate the impact of the high viscosity of agarose required for mtDNA retention on the throughput of microfluidics, we developed a parallelized device, successfully achieving ~95 % mtDNA retention from single cells within our microbeads at >700,000 drops/minute. To demonstrate utility, we analyzed specific regions of the single-mtDNA using a multiplexed rolling circle amplification (RCA) assay. We demonstrated compatibility with both microscopy, for digital counting of individual RCA products, and flow cytometry for higher throughput analysis.

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.

Development and future of droplet microfluidics

Over the past two decades, advances in droplet-based microfluidics have facilitated new approaches to process and analyze samples with unprecedented levels of precision and throughput. A wide variety of applications has been inspired across multiple disciplines ranging from materials science to biology. Understanding the dynamics of droplets enables optimization of microfluidic operations and design of new techniques tailored to emerging demands. In this review, we discuss the underlying physics behind high-throughput generation and manipulation of droplets. We also summarize the applications in droplet-derived materials and droplet-based lab-on-a-chip biotechnology. In addition, we offer perspectives on future directions to realize wider use of droplet microfluidics in industrial production and biomedical analyses.

High-throughput single-cell, single-mitochondrial DNA assay using hydrogel droplet microfluidics

There is growing interest in understanding the biological implications of single cell heterogeneity and intracellular heteroplasmy of mtDNA, but current methodologies for single-cell mtDNA analysis limit the scale of analysis to small cell populations. Although droplet microfluidics have increased the throughput of single-cell genomic, RNA, and protein analysis, their application to sub-cellular organelle analysis has remained a largely unsolved challenge. Here, we introduce an agarose-based droplet microfluidic approach for single-cell, single-mtDNA analysis, which allows simultaneous processing of hundreds of individual mtDNA molecules within >10,000 individual cells. Our microfluidic chip encapsulates individual cells in agarose beads, designed to have a sufficiently dense hydrogel network to retain mtDNA after lysis and provide a robust scaffold for subsequent multi-step processing and analysis. To mitigate the impact of the high viscosity of agarose required for mtDNA retention on the throughput of microfluidics, we developed a parallelized device, successfully achieving ~95% mtDNA retention from single cells within our microbeads at >700,000 drops/minute. To demonstrate utility, we analyzed specific regions of the single mtDNA using a multiplexed rolling circle amplification (RCA) assay. We demonstrated compatibility with both microscopy, for digital counting of individual RCA products, and flow cytometry for higher throughput analysis.

Pushing the limits of microfluidic droplet production efficiency: engineering microchannels with seamlessly implemented 3D inverse colloidal crystals

Although droplet microfluidics has been studied for the past two decades, its applications are still limited due to the low productivity of microdroplets resulting from the low integration of planar microchannel structures. In this study, a microfluidic system implementing inverse colloidal crystals (ICCs), a spongious matrix with regularly and densely formed three-dimensional (3D) interconnected micropores, was developed to significantly increase the throughput of microdroplet generation. A new bottom-up microfabrication technique was developed to seamlessly integrate the ICCs into planar microchannels by accumulating non-crosslinked spherical PMMA microparticles as sacrificial porogens in a selective area of a mold and later dissolving them. We have demonstrated that the densely arranged micropores on the spongious ICC of the microchannel function as massively parallel micronozzles, enabling droplet formation on the order of >10 kHz. Droplet size could be adjusted by flow conditions, fluid properties, and micropore size, and biopolymer particles composed of polysaccharides and proteins were produced. By further parallelization of the unit structures, droplet formation on the order of >100 kHz was achieved. The presented approach is an upgrade of the existing droplet microfluidics concept, not only in terms of its high throughput, but also in terms of ease of fabrication and operation.

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.

Designable microfluidic ladder networks from backstepping microflow analysis for mass production of monodisperse microdroplets

Controllable mass production of monodisperse droplets plays a key role in numerous fields ranging from scientific research to industrial application. Microfluidic ladder networks show great potential in mass production of monodisperse droplets, but their design with uniform microflow distribution remains challenging due to the lack of a rational design strategy. Here an effective design strategy based on backstepping microflow analysis (BMA) is proposed for the rational development of microfluidic ladder networks for mass production of controllable monodisperse microdroplets. The performance of our BMA rule for rational microfluidic ladder network design is demonstrated by using an existing analogism-derived rule that is widely used for the design of microfluidic ladder networks as the control group. The microfluidic ladder network designed by the BMA rule shows a more uniform flow distribution in each branch microchannel than that designed by the existing rule, as confirmed by single-phase flow simulation. Meanwhile, the microfluidic ladder network designed by the BMA rule allows mass production of droplets with higher size monodispersity in a wider window of flow rates and mass production of polymeric microspheres from such highly monodisperse droplet templates. The proposed BMA rule provides new insights into the microflow distribution behaviors in microfluidic ladder networks based on backstepping microflow analysis and provides a rational guideline for the efficient development of microfluidic ladder networks with uniform flow distribution for mass production of highly monodisperse droplets. Moreover, the BMA method provides a general analysis strategy for microfluidic networks with parallel multiple microchannels for rational scale-up.

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.

Microfluidic Formulation of Topological Hydrogels for Microtissue Engineering

Microfluidics has recently emerged as a powerful tool in generation of submillimeter-sized cell aggregates capable of performing tissue-specific functions, so-called microtissues, for applications in drug testing, regenerative medicine, and cell therapies. In this work, we review the most recent advances in the field, with particular focus on the formulation of cell-encapsulating microgels of small "dimensionalities": "0D" (particles), "1D" (fibers), "2D" (sheets), etc., and with nontrivial internal topologies, typically consisting of multiple compartments loaded with different types of cells and/or biopolymers. Such structures, which we refer to as topological hydrogels or topological microgels (examples including core-shell or Janus microbeads and microfibers, hollow or porous microstructures, or granular hydrogels) can be precisely tailored with high reproducibility and throughput by using microfluidics and used to provide controlled "initial conditions" for cell proliferation and maturation into functional tissue-like microstructures. Microfluidic methods of formulation of topological biomaterials have enabled significant progress in engineering of miniature tissues and organs, such as pancreas, liver, muscle, bone, heart, neural tissue, or vasculature, as well as in fabrication of tailored microenvironments for stem-cell expansion and differentiation, or in cancer modeling, including generation of vascularized tumors for personalized drug testing. We review the available microfluidic fabrication methods by exploiting various cross-linking mechanisms and various routes toward compartmentalization and critically discuss the available tissue-specific applications. Finally, we list the remaining challenges such as simplification of the microfluidic workflow for its widespread use in biomedical research, bench-to-bedside transition including production upscaling, further in vivo validation, generation of more precise organ-like models, as well as incorporation of induced pluripotent stem cells as a step toward clinical applications.

A double-step emulsification device for direct generation of double emulsions

In microfluidic step emulsification, the size of droplets generated in the dripping regime is predominantly determined by the nozzle's height and only weakly depends on the applied flow rates or liquid properties. While the generation of monodisperse emulsions at high throughput using step emulsifiers has been well established, the generation of double emulsions, i.e., liquid core-shell structures, is still challenging. Here, we demonstrate a novel double-step emulsification method for the direct generation of multi-core double-emulsions and provide a predictive model for the number of cores. While the mechanism of the formation of the core droplets or empty shell droplets follows the well-established scenario of simple step emulsification, the formation of double-emulsion droplets is strongly affected by the presence of the cores. Passing of the cores through the narrowing neck of the shell postpones shell pinch-off. In particular, we demonstrate that our system can be used for the generation of arbitrary large, tightly packed droplet clusters consisting of a controllable number of droplets. Finally, we discuss the options of upscaling the system for high-throughput generation of tailored double emulsions.

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.

Large-scale single-cell encapsulation in microgels through metastable droplet-templating combined with microfluidic-integration

Current techniques for the generation of cell-laden microgels are limited by numerous challenges, including poorly uncontrolled batch-to-batch variations, processes that are both labor- and time-consuming, the high expense of devices and reagents, and low production rates; this hampers the translation of laboratory findings to clinical applications. To address these challenges, we develop a droplet-based microfluidic strategy based on metastable droplet-templating and microchannel integration for the substantial large-scale production of single cell-laden alginate microgels. Specifically, we present a continuous processing method for microgel generation by introducing amphiphilic perfluoronated alcohols to obtain metastable emulsion droplets as sacrificial templates. In addition, to adapt to the metastable emulsion system, integrated microfluidic chips containing 80 drop-maker units are designed and optimized based on the computational fluid dynamics simulation. This strategy allows single cell encapsulation in microgels at a maximum production rate of 10 ml hr-1 of cell suspension while retaining cell viability and functionality. These results represent a significant advance toward using cell-laden microgels for clinical-relevant applications, including cell therapy, tissue regeneration and 3D bioprinting.

Control of Drug-Excipient Particle Attributes with Droplet Microfluidic-based Extractive Solidification Enables Improved Powder Rheology

PURPOSE

Industrial implementation of continuous oral solid dosage form manufacturing has been impeded by the poor powder flow properties of many active pharmaceutical ingredients (APIs). Microfluidic droplet-based particle synthesis is an emerging particle engineering technique that enables the production of neat or composite microparticles with precise control over key attributes that affect powder flowability, such as particle size distribution, particle morphology, composition, and the API's polymorphic form. However, the powder properties of these microparticles have not been well-studied due to the limited mass throughputs of available platforms. In this work, we produce spherical API and API-composite microparticles at high mass throughputs, enabling characterization and comparison of the bulk powder flow properties of these materials and greater understanding of how particle-scale attributes correlate with powder rheology.

METHODS

A multi-channel emulsification device and an extractive droplet-based method are harnessed to synthesize spherical API and API-excipient particles of artemether. As-received API and API crystallized in the absence of droplet confinement are used as control cases. Particle attributes are characterized for each material and correlated with a comprehensive series of powder rheology tests.

RESULTS

The droplet-based processed artemether particles are observed to be more flowable, less cohesive, and less compressible than conventionally synthesized artemether powder. Co-processing the API with polycaprolactone to produce composite microparticles reduces the friction of the powder on stainless steel, a common equipment material.

CONCLUSIONS

Droplet-based extractive solidification is an attractive particle engineering technique for improving powder processing and may aid in the implementation of continuous solid dosage form manufacturing.

High throughput production of microcapsules using microfluidics for self-healing of cementitious materials

Capsule-based self-healing of cementitious materials is an effective way of healing cracks, significantly extending the life of structures, without imposing changes due to the incorporation of capsules into products during mixing. The methodologies currently being used for the development of capsules with a liquid core as a healing agent yield a wide range of sizes and shell thicknesses for the microcapsules, preventing a detailed assessment and optimisation of the microcapsule size and its effects. Uniquely, microfluidic technology offers precise control over the size and shell thickness through the formation of double emulsions. The drawback is that only small quantities of material can be typically produced. Here, by using paralleled junctions in a microfluidic device, high throughput production of materials was achieved, focusing for the first time on self-healing of cementitious materials. A microfluidic chip was assembled with 4 channels in parallel and selected hydrophobicity for the formation of the double emulsions. A coefficient of variation below 2.5% was observed for the 4 junctions, demonstrating the formation of monodisperse capsules. The control over the size and shell thickness by adjusting the flow rates was demonstrated, yielding capsules with an outer diameter of 615-630 μm and a shell thickness varying between 50 and 127 μm. By using triethanolamine as a surfactant, capsules with an aqueous core were produced. Furthermore, by selecting PEA, an acrylate with low tensile strength, the capsules embedded in the cement paste were successfully triggered to release the healing agent by crack formation. Capsules were successfully produced continuously for 7 h, with inner and outer diameters of 500 ± 31 μm and 656 ± 9 μm at a production rate of ∼13 g h^-1 and a yield of around 80%. With these results and considering up to 6 chips in parallel, the production rate could be up to 1.5 kg per day. This demonstrates the huge potential of the microfluidic device with unique features to produce sufficiently large quantities of microcapsules for laboratory-scale assessment of self-healing performance.

Three months extended-release microspheres prepared by multi-microchannel microfluidics in beagle dog models

To evaluate in vivo drug release profiles in beagle dogs, finasteride-loaded PLGA microspheres were prepared using a novel method of IVL-PPF Microsphere® microfluidic device. Briefly, the dispersed phase (PLGA and finasteride in dichloromethane) was mixed with the continuous phase (0.25% w/v PVA aqueous solution) in the parallelized microchannels. After lyophilization, the diameter of the microspheres was around 40 μm (PLGA 7502A or 5002A) and around 30 µm (PLGA/PLA02A mixture). Their CV and span values suggested a narrow size distribution in repeated batch preparations. The in vivo drug release from the PLGA microspheres exhibited three substantial phases: an initial burst, a moderate release, and then a plateau. The microspheres based on PLGA 7502A (75:25 co-polymer) demonstrated extended drug release for around 1 month with a minimized initial burst release compared to PLGA 5002A (50:50 co-polymer). Moreover, the in vivo drug release profile in beagle dogs was proportionally related to the amount of drug loading. Furthermore, the addition of PLA02A into the fabrication of the microsphere synergistically extended the drug release up to 3 months. These results demonstrated the value of this method to achieve uniform microspheres and extend the drug release properties with interpretative in vivo PK profiles.

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

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

Hydrogel foams from liquid foam templates: Properties and optimisation

Hydrogel foams are an important sub-class of macroporous hydrogels. They are commonly obtained by integrating closely-packed gas bubbles of 10-1000 μm into a continuous hydrogel network, leading to gas volume fractions of more than 70% in the wet state and close to 100% in the dried state. The resulting wet or dried three-dimensional architectures provide hydrogel foams with a wide range of useful properties, including very low densities, excellent absorption properties, a large surface-to-volume ratio or tuneable mechanical properties. At the same time, the hydrogel may provide biodegradability, bioabsorption, antifungal or antibacterial activity, or controlled drug delivery. The combination of these properties are increasingly exploited for a wide range of applications, including the biomedical, cosmetic or food sector. The successful formulation of a hydrogel foam from an initially liquid foam template raises many challenging scientific and technical questions at the interface of hydrogel and foam research. Goal of this review is to provide an overview of the key notions which need to be mastered and of the state of the art of this rapidly evolving field at the interface between chemistry and physics.

Microfluidics for Drug Development: From Synthesis to Evaluation

Drug development is a long process whose main content includes drug synthesis, drug delivery, and drug evaluation. Compared with conventional drug development procedures, microfluidics has emerged as a revolutionary technology in that it offers a miniaturized and highly controllable environment for bio(chemical) reactions to take place. It is also compatible with analytical strategies to implement integrated and high-throughput screening and evaluations. In this review, we provide a comprehensive summary of the entire microfluidics-based drug development system, from drug synthesis to drug evaluation. The challenges in the current status and the prospects for future development are also discussed. We believe that this review will promote communications throughout diversified scientific and engineering communities that will continue contributing to this burgeoning field.

Monodisperse Selectively Permeable Hydrogel Capsules Made from Single Emulsion Drops

Capsules are often used to protect chemical and biological entities from the environment, to control the timing and location of their release, or to facilitate the collection of waste. Their performance depends on the thickness and composition of their shells, which can be closely controlled if capsules are made from double emulsion drops that are produced with microfluidics. However, the fabrication of such double emulsions is delicate, limiting throughput and increasing costs. Here, a fast, scalable method to produce monodisperse microcapsules possessing mechanically robust, thin, semipermeable hydrogel shells from single emulsion drops is introduced. This is achieved by selectively polymerizing reagents in close proximity to the drop surface to form a biocompatible 1.6 μm-thick hydrogel shell that encompasses a liquid core. The size-selective permeability of the shell enables the growth of living yeast and bacteria in their cores. Moreover, if capsules are loaded with adsorbents, they can repetitively remove waste products from water. The simplicity and robustness of the capsule fabrication makes the process scalable and cost effective. It has thus the potential to extend the use of calibrated capsules possessing well-defined dimensions to cost sensitive fields, including food, waste water treatment, or oil recovery.

Recent advances in the design of microfluidic technologies for the manufacture of drug releasing particles

Drug releasing particles are valued for their ability to deliver therapeutics to targeted locations and for their controllable release patterns. The development of microfluidic technologies, which are designed specifically to manipulate small amounts of fluids, to manufacture particles for drug delivery applications reflects a recent trend due to the advantages they confer in terms of control over particle size and material composition. This review takes a comprehensive look at the different types of microfluidic devices used to fabricate such particles from different types of biomaterials, and at how the on-chip features enable the production of particles with different types of properties. The review concludes by suggesting avenues for future work that will enable these technologies to fulfill their potential and be used in industrial settings for the manufacture of drug releasing particles with unique capabilities.

Considerations Using Additive Manufacture of Emulsion Inks to Produce Respiratory Protective Filters Against Viral Respiratory Tract Infections Such as the COVID-19 Virus

This review paper explores the potential of combining emulsion-based inks with additive manufacturing (AM) to produce filters for respiratory protective equipment (RPE) in the fight against viral and bacterial infections of the respiratory tract. The value of these filters has been highlighted by the current severe acute respiratory syndrome coronavirus-2 crisis where the importance of protective equipment for health care workers cannot be overstated. Three-dimensional (3D) printing of emulsions is an emerging technology built on a well-established field of emulsion templating to produce porous materials such as polymerized high internal phase emulsions (polyHIPEs). PolyHIPE-based porous polymers have tailorable porosity from the submicron to 100 s of µm. Advances in 3D printing technology enables the control of the bulk shape while a micron porosity is controlled independently by the emulsion-based ink. Herein, we present an overview of the current polyHIPE-based filter applications. Then, we discuss the current use of emulsion templating combined with stereolithography and extrusion-based AM technologies. The benefits and limitation of various AM techniques are discussed, as well as considerations for a scalable manufacture of a polyHIPE-based RPE.

Surfactant-Laden Janus Droplets with Tunable Morphologies and Enhanced Stability for Fabricating Lens-Shaped Polymeric Microparticles

Janus droplets can function as excellent templates for fabricating physically and chemically anisotropic particles. Here, we report new surfactant-laden Janus droplets with curvature controllability and enhanced stability against coalescence, suitable for fabricating shape-anisotropic polymer microparticles. Using a microfluidic flow-focusing device on a glass chip, nanoliter-sized biphasic droplets, comprising an acrylate monomer segment and a silicone-oil (SO) segment containing a surfactant, were produced in a co-flowing aqueous polyvinyl alcohol (PVA) solution. At equilibrium, the droplets formed a Janus geometry based on the minimization of interfacial energy, and each of the two Janus segments were uniform in size with coefficient-of-variation values below 3%. By varying the concentration of the surfactant in the SO phase, the curvature of the interface between the two lobes could be shifted among concave, planar, and convex shapes. In addition, the Janus droplets exhibited significantly improved stability against coalescence compared with previously reported Janus droplets carrying no surfactant that coalesced rapidly. Finally, via off-chip photopolymerization, concave-convex, planar-convex, and biconvex lens-shaped particles were fabricated.

MRBLES 2.0: High-throughput generation of chemically functionalized spectrally and magnetically encoded hydrogel beads using a simple single-layer microfluidic device

The widespread adoption of bead-based multiplexed bioassays requires the ability to easily synthesize encoded microspheres and conjugate analytes of interest to their surface. Here, we present a simple method (MRBLEs 2.0) for the efficient high-throughput generation of microspheres with ratiometric barcode lanthanide encoding (MRBLEs) that bear functional groups for downstream surface bioconjugation. Bead production in MRBLEs 2.0 relies on the manual mixing of lanthanide/polymer mixtures (each of which comprises a unique spectral code) followed by droplet generation using single-layer, parallel flow-focusing devices and the off-chip batch polymerization of droplets into beads. To streamline downstream analyte coupling, MRBLEs 2.0 crosslinks copolymers bearing functional groups on the bead surface during bead generation. Using the MRBLEs 2.0 pipeline, we generate monodisperse MRBLEs containing 48 distinct well-resolved spectral codes with high throughput (>150,000/min and can be boosted to 450,000/min). We further demonstrate the efficient conjugation of oligonucleotides and entire proteins to carboxyl MRBLEs and of biotin to amino MRBLEs. Finally, we show that MRBLEs can also be magnetized via the simultaneous incorporation of magnetic nanoparticles with only a minor decrease in the potential code space. With the advantages of dramatically simplified device fabrication, elimination of the need for custom-made equipment, and the ability to produce spectrally and magnetically encoded beads with direct surface functionalization with high throughput, MRBLEs 2.0 can be directly applied by many labs towards a wide variety of downstream assays, from basic biology to diagnostics and other translational research.

Microtechnological Tools to Achieve Sustainable Food Processes, Products, and Ingredients

One of the major challenges we face as humankind is supplying a growing world population with sufficient and healthy foods. Although from a worldwide perspective sufficient food is produced, locally, the situation can be dire. Furthermore, the production needs to be increased in a sustainable manner for future generations, which also implies prevention of food waste, and making better use of the available resources. How to contribute to this as food technologists is an ultimate question, especially since the tools that can investigate processes at relevant time scales, and dimensions, are lacking. Here we propose the use of microtechnology and show examples of how this has led to new insights in the fields of ingredient isolation (filtration), and emulsion/foam formation, which will ultimately lead to better-defined products. Furthermore, microfluidic tools have been applied for testing ingredient functionality, and for this, various examples are discussed that will expectedly contribute to making better use of more sustainably sourced starting materials (e.g., novel protein sources). This review will wrap up with a section in which we discuss future developments. We expect that it will be possible to link food properties to the effects that foods create in vivo. We thus expand the scope of this review that is technical in nature, toward physiological functionality, and ultimately to rational food design that is targeted to improve human health.

Engineering 3D parallelized microfluidic droplet generators with equal flow profiles by computational fluid dynamics and stereolithographic printing

Microfluidic droplet generators excel in generating monodisperse micrometer-sized droplets and particles. However, the low throughput of conventional droplet generators hinders their clinical and industrial translation. Current approaches to parallelize microdevices are challenged by the two-dimensional nature of the standard fabrication methods. Here, we report the facile production of three-dimensionally (3D) parallelized microfluidic droplet generators consisting of stacked and radially multiplexed channel designs. Computational fluid dynamics simulations form the design basis for a microflow distributor that ensures similar flow rates through all droplet generators. Stereolithography is the selected technique to fabricate microdevices, which enables the manufacturing of hollow channels with dimensions as small as 50 μm. The microdevices could be operated up to 4 bars without structural damage, including deformation of channels, or leakage of the on-chip printed Luer-Lok type connectors. The printed microdevices readily enable the production of water-in-oil emulsions, as well as polymer containing droplets that act as templates for both solid and core-shell hydrogel microparticles. The cytocompatibility of the 3D printed device is demonstrated by encapsulating mesenchymal stem cells in hydrogel microcapsules, which results in the controllable formation of stem cell spheroids that remain viable and metabolically active for at least 21 days. Thus, the unique features of stereolithography fabricated microfluidic devices allow for the parallelization of droplet generators in a simple yet effective manner by enabling the realization of (complex) 3D designs.

Parallelizable microfluidic dropmakers with multilayer geometry for the generation of double emulsions

Microfluidic devices enable the production of uniform double emulsions with control over droplet size and shell thickness. However, the limited production rate of microfluidic devices precludes the use of monodisperse double emulsions for industrial-scale applications, which require large quantities of droplets. To increase throughput, devices can be parallelized to contain many dropmakers operating simultaneously in one chip, but this is challenging to do for double emulsion dropmakers. Production of double emulsions requires dropmakers to have both hydrophobic and hydrophilic channels, requiring spatially precise patterning of channel surface wettability. Precise wettability patterning is difficult for devices containing multiple dropmakers, posing a significant challenge for parallelization. In this paper, we present a multilayer dropmaker geometry that greatly simplifies the process of producing microfluidic devices with excellent spatial control over channel wettability. Wettability patterning is achieved through the independent functionalization of channels in each layer prior to device assembly, rendering the dropmaker with a precise step between hydrophobic and hydrophilic channels. This device geometry enables uniform wettability patterning of parallelized dropmakers, providing a scalable approach for the production of double emulsions.

Self-optimizing parallel millifluidic reactor for scaling nanoparticle synthesis

A parallel millifluidic reactor for automated scaled-up syntheses of photoluminescent nanoparticles with self-optimizing feedback and throughput around 1 L h⁻¹.

Streamlined digital bioassays with a 3D printed sample changer

Off-chip sample changer device increase the sample throughput of droplet digital bioassays.

Food Structure Development in Emulsion Systems

A number of food products exist, in part or entirely, as emulsions, while others are present in an emulsified state at some point during their production/formation. Mayonnaise, butter, margarine, salad dressing, whipped cream, and ice cream represent some of the typical examples of emulsion-based foods. Controlled by both formulation and processing aspects, the emulsion architecture that is formed ultimately determines many of the attributes of the final food product. This chapter initially provides an overview of the basic constituents of emulsions and their influence on the microstructure and stability of conventional as well as more complex systems. The available spectrum of processing routes and characterization techniques currently utilized (or emerging) within the area of emulsions is then discussed. The chapter concludes with a concise outline of the relationship between food emulsion microstructure design and its performance (textural, rheological, sensorial, etc.).

Scalable Production of Monodisperse Functional Microspheres by Multilayer Parallelization of High Aspect Ratio Microfluidic Channels

Droplet microfluidics enables the generation of highly uniform emulsions with excellent stability, precise control over droplet volume, and morphology, which offer superior platforms over conventional technologies for material synthesis and biological assays. However, it remains a challenge to scale up the production of the microfluidic devices due to their complicated geometry and long-term reliability. In this study, we present a high-throughput droplet generator by parallelization of high aspect ratio rectangular structures, which enables facile and scalable generation of uniform droplets without the need to precisely control external flow conditions. A multilayer device is formed by stacking layer-by-layer of the polydimethylsiloxane (PDMS) replica patterned with parallelized generators. By feeding the sample fluid into the device immersed in the carrying fluid, we used the multilayer device with 1200 parallelized generators to generate monodisperse droplets (~45 μm in diameter with a coefficient of variation <3%) at a frequency of 25 kHz. We demonstrate this approach is versatile for a wide range of materials by synthesis of polyacrylamide hydrogel and Poly (l-lactide-co-glycolide) (PLGA) through water-in-oil (W/O) and oil-in-water (O/W) emulsion templates, respectively. The combined scalability and robustness of such droplet emulsion technology is promising for production of monodisperse functional materials for large-scale applications.

Automated detection and sorting of microencapsulation via machine learning

Microfluidic-based microencapsulation requires significant oversight to prevent material and quality loss due to sporadic disruptions in fluid flow that routinely arise. State-of-the-art microcapsule production is laborious and relies on experts to monitor the process, e.g. through a microscope. Unnoticed defects diminish the quality of collected material and/or may cause irreversible clogging. To address these issues, we developed an automated monitoring and sorting system that operates on consumer-grade hardware in real-time. Using human-labeled microscope images acquired during typical operation, we train a convolutional neural network that assesses microencapsulation. Based on output from the machine learning algorithm, an integrated valving system collects desirable microcapsules or diverts waste material accordingly. Although the system notifies operators to make necessary adjustments to restore microencapsulation, we can extend the system to automate corrections. Since microfluidic-based production platforms customarily collect image and sensor data, machine learning can help to scale up and improve microfluidic techniques beyond microencapsulation.

Droplet-based microfluidics systems in biomedical applications

Microfluidics has made a very impressive progress in the past decades due to its unique and instinctive advantages. Droplet-based microfluidic systems show excellent compatibility with many chemical and biological reagents and are capable of performing variety of operations that can implement microreactor, complex multiple core-shell structure, and many applications in biomedical research such as drug encapsulation, targeted drug delivery systems, and multifunctionalization on carriers. Droplet-based systems have been directly used to synthesize particles and encapsulate many biological entities for biomedicine applications due to their powerful encapsulation capability and facile versatility. In this paper, we review its origin, deviation, and evolution to draw a clear future, especially for droplet-based biomedical applications. This paper will focus on droplet generation, variations and complication as starter, and logistically lead to the numerous typical applications in biomedical research. Finally, we will summarize both its challenge and future prospects relevant to its droplet-based biomedical applications.

Challenges and Recent Progress in Oral Drug Delivery Systems for Biopharmaceuticals

Routes of drug administration and the corresponding physicochemical characteristics of a given route play significant roles in therapeutic efficacy and short term/long term biological effects. Each delivery method has favorable aspects and limitations, each requiring a specific delivery vehicles design. Among various routes, oral delivery has been recognized as the most attractive method, mainly due to its potential for solid formulations with long shelf life, sustained delivery, ease of administration and intensified immune response. At the same time, a few challenges exist in oral delivery, which have been the main research focus in the field in the past few years. The present work concisely reviews different administration routes as well as the advantages and disadvantages of each method, highlighting why oral delivery is currently the most promising approach. Subsequently, the present work discusses the main obstacles for oral systems and explains the most recent solutions proposed to deal with each issue.

Multiple splitting of droplets using multi-furcating microfluidic channels

Removing volumes from droplets is a challenging but critical step in many droplet-based applications. Geometry-mediated droplet splitting has the potential to reliably divide droplets and thus facilitate the implementation of this step. In this paper, we report the design of multi-furcating microfluidic channels for efficient droplet splitting. We studied the splitting regimes as the size of the mother droplets varied and investigated the dependence of the transition between splitting regimes on the capillary number and the dimensionless droplet length. We found that the results obtained with our device agreed with the reported dimensionless analysis law in T-junctions. We further investigated the effect of channel lengths on the volume allocation in branch channels and achieved droplet splitting with various splitting ratios. This study proposed an efficient on-demand droplet splitting method and the findings could potentially be applied in washing steps in droplet-based biological assays or assays that require aliquot.

Methods for producing microstructured hydrogels for targeted applications in biology

Hydrogels have been broadly studied for applications in clinically motivated fields such as tissue regeneration, drug delivery, and wound healing, as well as in a wide variety of consumer and industry uses. While the control of mechanical properties and network structures are important in all of these applications, for regenerative medicine applications in particular, matching the chemical, topographical and mechanical properties for the target use/tissue is critical. There have been multiple alternatives developed for fabricating materials with microstructures with goals of controlling the spatial location, phenotypic evolution, and signaling of cells. The commonly employed polymers such as poly(ethylene glycol) (PEG), polypeptides, and polysaccharides (as well as others) can be processed by various methods in order to control material heterogeneity and microscale structures. We review here the more commonly used polymers, chemistries, and methods for generating microstructures in biomaterials, highlighting the range of possible morphologies that can be produced, and the limitations of each method. With a focus in liquid-liquid phase separation, methods and chemistries well suited for stabilizing the interface and arresting the phase separation are covered. As the microstructures can affect cell behavior, examples of such effects are reviewed as well. STATEMENT OF SIGNIFICANCE: Heterogeneous hydrogels with enhanced matrix complexity have been studied for a variety of biomimetic materials. A range of materials based on poly(ethylene glycol), polypeptides, proteins, and/or polysaccharides, have been employed in the studies of materials that by virtue of their microstructure, can control the behaviors of cells. Methods including microfluidics, photolithography, gelation in the presence of porogens, and liquid-liquid phase separation, are presented as possible strategies for producing materials, and their relative advantages and disadvantages are discussed. We also describe in more detail the various processes involved in LLPS, and how they can be manipulated to alter the kinetics of phase separation and to yield different microstructured materials.

Detection and Automation Technologies for the Mass Production of Droplet Biomicrofluidics

Droplet microfluidics utilizes two immiscible flows to generate small droplets with the diameter of a few to a few hundred micrometers. These droplets are promising tools for biomedical engineering because of the high throughput and the ease to finely tune the microenvironments. In addition to the great success of droplet biomicrofluidics in the proof-of-concept biosensing, regenerative medicine, and drug delivery, few droplet biomicrofluidic devices have a transformative impact on the industrial and clinical applications. The main issues are the low volume throughput and the lack of proper methods for quality control and automation. This review covers the methodologies for the mass production, detection, and automation of droplet generators. Recent advances in droplet mass production using parallelized devices and modified junction structures are discussed. Detection techniques, including optical and electrical detection methods, are comprehensively reviewed in detail. Newly emerged droplet closed-loop control systems are surveyed to highlight the progress in system integration and automation. Overall, with the advances in parallel droplet generation, highly sensitive detection, and robust closed-loop regulation, it is anticipated that the productivity and reliability of droplet biomicrofluidics will be significantly improved to meet the industrial and clinical needs.

Quantifying phenotypes in single cells using droplet microfluidics

This book chapter describes the use of droplet microfluidics to phenotype single cells. The basic process flow includes the encapsulation of single cells with a specific probe into aqueous micro-droplets suspended in a biocompatible oil. The probe is chosen to measure the phenotype of interest. After incubation, the encapsulated cell turns the probe fluorescent and renders the entire droplet fluorescent. Enumerating drops that are fluorescent quantifies the concentration of cells possessing the phenotype of interest. Examining the distribution of fluorescence further allows one to quantify the heterogeneity among the cell population.

Wetting controls of droplet formation in step emulsification

The formation of droplets is ubiquitous in many natural and industrial processes and has reached an unprecedented level of control with the emergence of milli- and microfluidics. Although important insight into the mechanisms of droplet formation has been gained over the past decades, a sound understanding of the physics underlying this phenomenon and the effect of the fluid's flow and wetting properties on the droplet size and production rate is still missing, especially for the widely applied method of step emulsification. In this work, we elucidate the physical controls of microdroplet formation in step emulsification by using the wetting of fluidic channels as a tunable parameter to explore a broad set of emulsification conditions. With the help of high-speed measurements, we unequivocally show that the final droplet pinch-off is triggered by a Rayleigh-Plateau-type instability. The droplet size, however, is not determined by the Rayleigh-Plateau breakup, but by the initial wetting regime, where the fluid's contact angle plays a crucial role. We develop a physical theory for the wetting process, which closely describes our experimental measurements without invoking any free fit parameter. Our theory predicts the initiation of the Rayleigh-Plateau breakup and the transition from dripping to jetting as a function of the fluid's contact angle. Additionally, the theory solves the conundrum why there is a minimal contact angle of α = 2π/3 = 120° for which droplets can form.