Continuous flow synthesis of metal nanowires: protocols, engineering aspects of scale-up and applications

This review comprehensively covers the translation from batch to continuous flow synthesis of metal nanowires (i.e., silver, copper, gold, and platinum nanowires) and their diverse applications across various sectors. Metal nanowires have attracted significant attention owing to their versatility and feasibility for large-scale synthesis. The efficacy of flow chemistry in nanomaterial synthesis has been extensively demonstrated over the past few decades. Continuous flow synthesis offers scalability, high throughput screening, and robust and reproducible synthesis procedures, making it a promising technology. Silver nanowires, widely used in flexible electronics, transparent conductive films, and sensors, have benefited from advancements in continuous flow synthesis aimed at achieving high aspect ratios and uniform diameters, though challenges in preventing agglomeration during large-scale production remain. Copper nanowires, considered as a cost-effective alternative to silver nanowires for conductive materials, have benefited from continuous flow synthesis methods that minimize oxidation and enhance stability, yet scaling up these processes requires precise control of reducing environments and copper ion concentration. A critical evaluation of various metal nanowire ink formulations is conducted, aiming to identify formulations that exhibit superior properties with lower metal solid content. This study delves into the intricacies of continuous flow synthesis methods for metal nanowires, emphasizing the exploration of engineering considerations essential for the design of continuous flow reactors. Furthermore, challenges associated with large-scale synthesis are addressed, highlighting the process-related issues.

Microfluidic-assisted preparation of PLGA nanoparticles loaded with insulin: a comparison with double emulsion solvent evaporation method

Poly lactic-co-glycolic acid (PLGA) is an ideal polymer for the delivery of small and macromolecule drugs. Conventional preparation methods of PLGA nanoparticles (NPs) result in poor control over NPs properties. In this research, a microfluidic mixer was designed to produce insulin-loaded PLGA NPs with tuned properties. Importantly; aggregation of the NPs through the mixer was diminished due to the coaxial mixing of the precursors. The micromixer allowed for the production of NPs with small size and narrow size distribution compared to the double emulsion solvent evaporation (DESE) method. Furthermore, encapsulation efficiency and loading capacity indicated a significant increase in optimized NPs produced through the microfluidic method in comparison to DESE method. NPs prepared by the microfluidic method were able to achieve a more reduction of trans-epithelial electrical resistance values in the Caco-2 cells compared to those developed by the DESE technique that leads to greater paracellular permeation. Compatibility and interaction between components were evaluated by differential scanning calorimetry and fourier transform infrared analysis. Also, the effect of NPs on cell toxicity was investigated using MTT test. Numerical simulations were conducted to analyze the effect of mixing patterns on the properties of the NPs. It was revealed that by decreasing flow rate ratio, i.e. flow rate of the organic phase to the flow rate of the aqueous phase, mixing of the two streams increases. As an alternative to the DESE method, high flexibility in modulating hydrodynamic conditions of the microfluidic mixer allowed for nanoassembly of NPs with superior insulin encapsulation at smaller particle sizes.

Roadmap on multifunctional materials for drug delivery

This Roadmap on drug delivery aims to cover some of the most recent advances in the field of materials for drug delivery systems (DDSs) and emphasizes the role that multifunctional materials play in advancing the performance of modern DDSs in the context of the most current challenges presented. The Roadmap is comprised of multiple sections, each of which introduces the status of the field, the current and future challenges faced, and a perspective of the required advances necessary for biomaterial science to tackle these challenges. It is our hope that this collective vision will contribute to the initiation of conversation and collaboration across all areas of multifunctional materials for DDSs. We stress that this article is not meant to be a fully comprehensive review but rather an up-to-date snapshot of different areas of research, with a minimal number of references that focus upon the very latest research developments.

One-Step Synthesis of Ultrasmall Nanoparticles in Glycerol as a Promising Green Solvent at Room Temperature Using Omega-Shaped Microfluidic Micromixers

Despite innovations in the synthesis protocol of nanoparticles (NPs), the size distribution and uniformity of particles still remain as crucial attributes. Homogeneous and rapid nucleation is a critical phenomenon to obtain monodisperse nanoparticles. Herein, we have carried out the synthesis of metal nanoparticles in a customized microfluidic (MF) chip, with 18 omega-shaped micromixers, by using glycerol as a promising green solvent and reducing agent at various concentrations (10-80%), and simultaneous comparison of the results from batch synthesis. Initially, mixing characterization for 10-80% glycerol was obtained by adjusting the Peclet (Pe) number. Further, the effect of the Pe number, time, and concentrations of polyvinylpyrrolidone, metal source, and glycerol on the NP size was investigated. Interestingly, the experimental findings depicted that by varying different parameters, the spherical nanoparticles with an average ultrasmall particle diameter of <2 nm were obtained at all glycerol concentrations (10-80%), as compared to batch synthesis (giving a yield of ∼10-fold larger particles). The mixing efficiency in this MF chip design was analyzed by using a fluorescent dye in glycerol, while the particle morphology and size were characterized by using dynamic light scattering, transmission electron microscopy, and ultraviolet-visible spectroscopy. Hence, compared to the conventional benchtop-assisted NP synthesis, this study unveils the significant effect of the microfluidic technique on the synthesis of ultrasmall and homogeneous nanoparticles in a single step, using an environmentally friendly solvent.

Sub-second synthesis of silver nanoparticles in 3D printed monolithic multilayered microfluidic chip: Enhanced chemiluminescence sensing predictions via machine learning algorithms

Futuristic microfluidics will require alternative ways to extend its potential in vast areas by integrating various facets such as automation of different subsystems, multiplexing, incorporation of cyber-physical capabilities, and rapid prototyping. On the rapid prototyping aspect, for the last decade, additive manufacturing (AM) or 3D printing (3DP) has advanced to become an alternative fabrication process for microfluidic devices, enabling industry-level abilities towards mass production. In this context, for the first time, this work demonstrates the fabrication of monolithic multilayer microfluidic devices (MMMD) from planar orientation (1 layer) to nonplanar (4 layers) monolithic microchannels. The developed MMM device was impeccable for synthesizing highly potentialized silver nanoparticles (AgNPs) in <1 s. Moreover, the transport of chemical species with laminar flow simulations was performed on the process along with the thorough characterizations of produced AgNPs, finding the mean AgNPs particle size of around 35 nm without any post-processing requirements. The well-known catalytic activity of AgNPs was leveraged to enhance weak chemiluminescence (CL) sensing signals by >1300 %, increasing CL sensitivity. Further, machine learning (ML) predictive models encouraged to obtain the experimental parameters without human intervention iterations for target-specific applications. The proposed methodology finds the potential to save resources, time, and enables automation with rapid prototyping, providing possibilities for mass fabrications.

A Microfluidic Approach for Synthesis of Silver Nanoparticles as a Potential Antimicrobial Agent in Alginate-Hyaluronic Acid-Based Wound Dressings

The recognized antimicrobial activity of silver nanoparticles is a well-studied property, especially when designing and developing biomaterials with medical applications. As biological activity is closely related to the physicochemical characteristics of a material, aspects such as particle morphology and dimension should be considered. Microfluidic systems in continuous flow represent a promising method to control the size, shape, and size distribution of synthesized nanoparticles. Moreover, using microfluidics widens the synthesis options by creating and controlling parameters that are otherwise difficult to maintain in conventional batch procedures. This study used a microfluidic platform with a cross-shape design as an innovative method for synthesizing silver nanoparticles and varied the precursor concentration and the purging speed as experimental parameters. The compositional and microstructural characterization of the obtained samples was carried out by X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and dynamic light scattering (DLS). Four formulations of alginate-based hydrogels with the addition of hyaluronic acid and silver nanoparticles were obtained to highlight the antimicrobial activity of silver nanoparticles and the efficiency of such a composite in wound treatment. The porous structure, swelling capacity, and biological properties were evaluated through physicochemical analysis (FT-IR and SEM) and through contact with prokaryotic and eukaryotic cells. The results of the physicochemical and biological investigations revealed desirable characteristics for performant wound dressings (i.e., biocompatibility, appropriate porous structure, swelling rate, and degradation rate, ability to inhibit biofilm formation, and cell growth stimulation capacity), and the obtained materials are thus recommended for treating chronic and infected wounds.

Efficient quenching sheds light on early stages of gold nanoparticle formation

The formation mechanism of plasmonic gold nanoparticles (Au NPs) by fast NaBH₄ induced reduction of the precursors is still under debate. In this work we introduce a simple method to access intermediate species of Au NPs by quenching the solid formation process at desired time periods. In this way, we take advantage of the covalent binding of glutathione on Au NPs to stop their growth. By applying a plethora of precise particle characterization techniques, we shed new light on the early stages of particle formation. The results of in situ UV/vis measurements, ex situ sedimentation coefficient analysis by analytical ultracentrifugation, size exclusion high performance liquid chromatography, electrospray ionization mass spectrometry supported by mobility classification and scanning transmission electron microscopy suggest an initial rapid formation of small non-plasmonic Au clusters with Au₁₀ as the main species followed by their growth to plasmonic Au NPs by agglomeration. The fast reduction of gold salts by NaBH₄ depends on mixing which is hard to control during the scale-up of batch processes. Thus, we transferred the Au NP synthesis to a continuous flow process with improved mixing. We observed that the mean volume particle sizes and the width of the particle size distribution decrease with increasing flow rate and thus higher energy input. Mixing- and reaction-controlled regimes are identified.

Functional nano-systems for transdermal drug delivery and skin therapy

Transdermal drug delivery is one of the least intrusive and patient-friendly ways for therapeutic agent administration. Recently, functional nano-systems have been demonstrated as one of the most promising strategies to treat skin diseases by improving drug penetration across the skin barrier and achieving therapeutically effective drug concentrations in the target cutaneous tissues. Here, a brief review of functional nano-systems for promoting transdermal drug delivery is presented. The fundamentals of transdermal delivery, including skin biology and penetration routes, are introduced. The characteristics of functional nano-systems for facilitating transdermal drug delivery are elucidated. Moreover, the fabrication of various types of functional transdermal nano-systems is systematically presented. Multiple techniques for evaluating the transdermal capacities of nano-systems are illustrated. Finally, the advances in the applications of functional transdermal nano-systems for treating different skin diseases are summarized.

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 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.

Silver Nanoparticle Synthesis Using an Inkjet Mixing System

Individual nanoscale silver particles were produced using an inkjet mixing system. First, the behaviors of colliding droplets were investigated to prepare to conduct the synthesis without splitting merged droplets. When small droplets collided, they merged to form droplets that stayed in a state of coalescence at a higher discharging velocity. In addition, by changing the orientation at the collision point, the droplet velocity could be increased. Then, silver nanoparticle synthesis was conducted under conditions that avoided droplet splitting. Smaller particles were produced by higher-velocity collisions for all the examined droplet sizes. When droplets were 50–100 μm, an average particle diameter of 2.5 nm was produced. In addition, when droplets of different sizes collided, they formed a continuous supply of precursor, which subsequently resulted in production of particles with uniform size.

Synthesis of monodisperse spherical AgNPs by ultrasound-intensified Lee-Meisel method, and quick evaluation via machine learning

Due to the high reactivity of Ag⁺ and uncontrolled growth process, the AgNPs produced by conventional Lee-Meisel method always exhibited larger particle size (30-200 nm) and polydisperse morphology (including spherical, triangular, and rod-like shape). An ultrasound-intensified Lee-Meisel (UILM) method is developed in this study to environmental-friendly and controllable synthesize monodisperse spherical AgNPs (~3.7 nm). Effects of Ag:citrate ratio (1:3 or 5:4), ultrasound power (300 to 1200 W) and reaction time (4 to 24 min) on the physical-chemical properties of AgNPs are investigated systematically. The transmission electron microscope (TEM) images, UV-Vis spectra, average particle size, zeta potential and pH value all demonstrate that crystallization and digestive ripening processes are facilitated in the presence of ultrasound irradiation. Therefore, both chemical reaction rate and mass transfer rate are enhanced to accelerate primary nucleation and inhibit uncontrolled particle growth, leading to the formation of monodisperse spherical AgNPs. Moreover, a machine learning approach - Decision Tree Regressor in conjunction with Shapley value analysis reveal the concentration of reactants is a more important feature affecting the particle.

Microfluidic synthesis of protein-loaded nanogels in a coaxial flow reactor using a design of experiments approach

Ionic gelation is commonly used to generate nanogels but often results in poor control over size and polydispersity. In this work we present a novel approach to the continuous manufacture of protein-loaded chitosan nanogels using microfluidics whereby we demonstrate high control and uniformity of the product characteristics. Specifically, a coaxial flow reactor (CFR) was employed to control the synthesis of the nanogels, comprising an inner microcapillary of internal diameter (ID) 0.595 mm and a larger outer glass tube of ID 1.6 mm. The CFR successfully facilitated the ionic gelation process via chitosan and lysozyme flowing through the inner microcapillary, while cross-linkers sodium tripolyphosphate (TPP) and 1-ethyl-2-(3-dimethylaminopropyl)-carbodiimide (EDC) flowed through the larger outer tube. In conjunction with the CFR, a four-factor three-level face-centered central composite design (CCD) was used to ascertain the relationship between various factors involved in nanogel production and their responses. Specifically, four factors including chitosan concentration, TPP concentration, flow ratio and lysozyme concentration were investigated for their effects on three responses (size, polydispersity index (PDI) and encapsulation efficiency (% EE)). A desirability function was applied to identify the optimum parameters to formulate nanogels in the CFR with ideal characteristics. Nanogels prepared using the optimal parameters were successfully produced in the nanoparticle range at 84 ± 4 nm, showing a high encapsulation efficiency of 94.6 ± 2.9% and a high monodispersity of 0.26 ± 0.01. The lysis activity of the protein lysozyme was significantly enhanced in the nanogels at 157.6% in comparison to lysozyme alone. Overall, the study has demonstrated that the CFR is a viable method for the synthesis of functional nanogels containing bioactive molecules.

Process Intensification Approach Using Microreactors for Synthesizing Nanomaterials-A Critical Review

Nanomaterials have found many applications due to their unique properties such as high surface-to-volume ratio, density, strength, and many more. This review focuses on the recent developments on the synthesis of nanomaterials using process intensification. The review covers the designing of microreactors, design principles, and fundamental mechanisms involved in process intensification using microreactors for synthesizing nanomaterials. The microfluidics technology operates in continuous mode as well as the segmented flow of gas–liquid combinations. Various examples from the literature are discussed in detail highlighting the advantages and disadvantages of microfluidics technology for nanomaterial synthesis.

Microfluidic-mediated nano-drug delivery systems: from fundamentals to fabrication for advanced therapeutic applications

Nano-drug delivery systems (NDDS) are functional drug-loaded nanocarriers extensively applied in the healthcare and pharmaceutical areas. Recently, microfluidics has been demonstrated as one of the most promising techniques to fabricate high-performance NDDS with uniform morphology, size and size distribution, reduced batch-to-batch variations and controllable drug delivering capacity. Here, a brief review of the microfluidic-mediated NDDS is presented. The fundamentals of microfluidics are first interpreted with an emphasis on the fluid characteristics, design and materials for microfluidic devices. Then a comprehensive and in-depth depiction of the microfluidic-mediated fabrications of controllable NDDS with well-tailored internal structures and integrated functions for controlled encapsulation and drug release are categorized and reviewed, with particular descriptions about the underlying formation mechanisms. Afterwards, recently appreciated representative applications of the microfluidic-mediated NDDS for delivering multiple drugs are systematically summarized. Finally, conclusions and perspectives on further advancing the microfluidic-mediated NDDS toward more powerful and versatile platforms for therapeutic applications are discussed.

Nanocrystal synthesis, μfluidic sample dilution and direct extraction of single emission linewidths in continuous flow

The rational design of semiconductor nanocrystal populations requires control of their emission linewidths, which are dictated by interparticle inhomogeneities and single-nanocrystal spectral linewidths. To date, research efforts have concentrated on minimizing the ensemble emission linewidths, however there is little knowledge about the synthetic parameters dictating single-nanocrystal linewidths. In this direction, we present a flow-based system coupled with an optical interferometry setup for the extraction of single nanocrystal properties. The platform has the ability to synthesize nanocrystals at high temperature <300 °C, adjust the particle concentration after synthesis and extract ensemble-averaged single nanocrystal emission linewidths using flow photon-correlation Fourier spectroscopy.

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.

Automated and Continuous Production of Polymeric Nanoparticles

Polymeric nanoparticles (NPs) are increasingly used as therapeutics, diagnostics, and building blocks in (bio)materials science. Current barriers to translation are limited control over NP physicochemical properties and robust scale-up of their production. Flow-based devices have emerged for controlled production of polymeric NPs, both for rapid formulation screening (~μg min-1) and on-scale production (~mg min-1). While flow-based devices have improved NP production compared to traditional batch processes, automated processes are desired for robust NP production at scale. Therefore, we engineered an automated coaxial jet mixer (CJM), which controlled the mixing of an organic stream containing block copolymer and an aqueous stream, for the continuous nanoprecipitation of polymeric NPs. The CJM was operated stably under computer control for up to 24 h and automated control over the flow conditions tuned poly(ethylene glycol)-block-polylactide (PEG5K -b-PLA20K ) NP size between ≈56 nm and ≈79 nm. In addition, the automated CJM enabled production of NPs of similar size (D h ≈ 50 nm) from chemically diverse block copolymers, PEG5K -b-PLA20K , PEG-block-poly(lactide-co-glycolide) (PEG5K -b-PLGA20K ), and PEG-block-polycaprolactone (PEG5K -b-PCL20K ), by tuning the flow conditions for each block copolymer. Further, the automated CJM was used to produce model nanotherapeutics in a reproducible manner without user intervention. Finally, NPs produced with the automated CJM were used to scale the formation of injectable polymer-nanoparticle (PNP) hydrogels, without modifying the mechanical properties of the PNP gel. In conclusion, the automated CJM enabled stable, tunable, and continuous production of polymeric NPs, which are needed for the scale-up and translation of this important class of biomaterials.

Macrofluidic Coaxial Flow Platforms to Produce Tunable Magnetite Nanoparticles: A Study of the Effect of Reaction Conditions and Biomineralisation Protein Mms6

Magnetite nanoparticles' applicability is growing extensively. However, simple, environmentally-friendly, tunable synthesis of monodispersed iron-oxide nanoparticles is challenging. Continuous flow microfluidic synthesis is promising; however, the microscale results in small yields and clogging. Here we present two simple macrofluidics devices (cast and machined) for precision magnetite nanoparticle synthesis utilizing formation at the interface by diffusion between two laminar flows, removing aforementioned issues. Ferric to total iron was varied between 0.2 (20:80 Fe³⁺:Fe²⁺) and 0.7 (70:30 Fe³⁺:Fe²⁺). X-ray diffraction shows magnetite in fractions from 0.2-0.6, with iron-oxide impurities in 0.7, 0.2 and 0.3 samples and magnetic susceptibility increases with increasing ferric content to 0.6, in agreement with each other and batch synthesis. Remarkably, size is tuned (between 20.5 nm to 6.5 nm) simply by increasing ferric ions ratio. Previous research shows biomineralisation protein Mms6 directs magnetite synthesis and controls size, but until now has not been attempted in flow. Here we report Mms6 increases magnetism, but no difference in particle size is seen, showing flow reduced the influence of Mms6. The study demonstrates a versatile yet simple platform for the synthesis of a vast range of tunable nanoparticles and ideal to study reaction intermediates and additive effects throughout synthesis.

Durable Antimicrobial Behaviour from Silver-Graphene Coated Medical Textile Composites

Silver nanoparticle (AgNP) and AgNP/reduced graphene oxide (rGO) nanocomposite impregnated medical grade polyviscose textile pads were formed using a facile, surface-mediated wet chemical solution-dipping process, without further annealing. Surfaces were sequentially treated in situ with a sodium borohydride (NaBH4) reducing agent, prior to formation, deposition, and fixation of Ag nanostructures and/or rGO nanosheets throughout porous non-woven (i.e., randomly interwoven) fibrous scaffolds. There was no need for stabilising agent use. The surface morphology of the treated fabrics and the reaction mechanism were characterised by Fourier transform infrared (FTIR) spectra, ultraviolet-visible (UV-Vis) absorption spectra, X-ray diffraction (XRD), Raman spectroscopy, dynamic light scattering (DLS) energy-dispersive X-ray analysis (EDS), and scanning electron microscopic (SEM). XRD and EDS confirmed the presence of pure-phase metallic silver. Variation of reducing agent concentration allowed control over characteristic plasmon absorption of AgNP while SEM imaging, EDS, and DLS confirmed the presence of and dispersion of Ag particles, with smaller agglomerates existing with concurrent rGO use, which also coincided with enhanced AgNP loading. The composites demonstrated potent antimicrobial activity against the clinically relevant gram-negative Escherichia coli (a key causative bacterial agent of healthcare-associated infections; HAIs). The best antibacterial rate achieved for treated substrates was 100% with only a slight decrease (to 90.1%) after 12 equivalent laundering cycles of standard washing. Investigation of silver ion release behaviours through inductively coupled plasmon optical emission spectroscopy (ICP-OES) and laundering durability tests showed that AgNP adhesion was aided by the presence of the rGO host matrix allowing for robust immobilisation of silver nanostructures with relatively high stability, which offered a rapid, convenient, scalable route to conformal NP-decorated and nanocomposite soft matter coatings.

Microfluidics and catalyst particles

In this review article, we discuss the latest advances and future perspectives of microfluidics for micro/nanoscale catalyst particle synthesis and analysis. In the first section, we present an overview of the different methods to synthesize catalysts making use of microfluidics and in the second section, we critically review catalyst particle characterization using microfluidics. The strengths and challenges of these approaches are highlighted with various showcases selected from the recent literature. In the third section, we give our opinion on the future perspectives of the combination of catalytic nanostructures and microfluidics. We anticipate that in the synthesis and analysis of individual catalyst particles, generation of higher throughput and better understanding of transport inside individual porous catalyst particles are some of the most important benefits of microfluidics for catalyst research.

Jet-mixing reactor for the production of monodisperse silver nanoparticles using a reduced amount of capping agent

The jet-mixing reactor can continuously produce monodisperse silver nanoparticles using limited amounts of capping agent.

Easy-to-perform and cost-effective fabrication of continuous-flow reactors and their application for nanomaterials synthesis

The translation of continuous-flow microreactor technology to the industrial environment has been limited by cost and complexity of the fabrication procedures and the requirement for specialised infrastructure. In the present study, we have developed a significantly more cost-effective and easy-to-perform fabrication method for the generation of optically transparent, continuous-flow reactors. The method combines 3D printing of master moulds with sealing of the PDMS channels' replica using a pressure-sensitive adhesive tape. Morphological characterisation of the 3D printed moulds was performed and reactors were fabricated with an approximately square-shaped cross-section of 1 mm². Notably, they were tested for operation over a wide range of volumetric flow rates, up to 20 ml/min. Moreover, the fabrication time (i.e., from design to the finished product) was <1 day, at an average material cost of ∼£5. The flow reactors have been applied to the production of both inorganic nanoparticles (silver nanospheres) and organic vesicular systems (liposomes), and their performance compared with reactors produced using more laborious fabrication methods. Numerical simulations were performed to characterise the transport of fluids and chemical species within the devices. The developed fabrication method is suitable for scaled-up fabrication of continuous-flow reactors, with potential for application in biotechnology and nanomedicine.

An engineering approach to synthesis of gold and silver nanoparticles by controlling hydrodynamics and mixing based on a coaxial flow reactor

In this work we present a detailed study of flow technology approaches that could open up new possibilities for nanoparticle synthesis. The synthesis of gold and silver nanoparticles (NPs) in a flow device based on a coaxial flow reactor (CFR) was investigated. The CFR comprised of an outer glass tube of 2 mm inner diameter (I.D.) and an inner glass tube whose I.D. varied between 0.142 and 0.798 mm. A split and recombine (SAR) mixer and coiled flow inverter (CFI) were further employed to alter the mixing conditions after the CFR. The 'Turkevich' method was used to synthesize gold NPs, with a CFR followed by a CFI. This assembly allows control over nucleation and growth through variation of residence time. Increasing the total flow rate from 0.25 ml min^-1 to 3 ml min^-1 resulted initially in a constant Au NP size, and beyond 1 ml min^-1 to a size increase of Au NPs from 17.9 ± 2.1 nm to 23.9 ± 4.7 nm. The temperature was varied between 60-100 °C and a minimum Au NP size of 17.9 ± 2.1 nm was observed at 80 °C. Silver NPs were synthesized in a CFR followed by a SAR mixer, using sodium borohydride to reduce silver nitrate in the presence of trisodium citrate. The SAR mixer provided an enhancement of the well-controlled laminar mixing in the CFR. Increasing silver nitrate concentration resulted in a decrease in Ag NP size from 5.5 ± 2.4 nm to 3.4 ± 1.4 nm. Different hydrodynamic conditions were studied in the CFR operated in isolation for silver NP synthesis. Increasing the Reynolds number from 132 to 530 in the inner tube created a vortex flow resulting in Ag NPs in the size range between 5.9 ± 1.5 nm to 7.7 ± 3.4 nm. Decreasing the inner tube I.D. from 0.798 mm to 0.142 mm resulted in a decrease in Ag NP size from 10.5 ± 4.0 nm to 4.7 ± 1.4 nm. Thus, changing the thickness of the inner stream enabled control over size of the Ag NPs.

Controllable synthesis of functional nanoparticles by microfluidic platforms for biomedical applications - a review

Nanoparticles have drawn significant attention in biomedicine due to their unique optical, thermal, magnetic and electrical properties which are highly related to their size and morphologies. Recently, microfluidic systems have shown promising potential to modulate critical stages in nanosynthesis, such as nucleation, growth and reaction conditions so that the size, size distribution, morphology, and reproducibility of nanoparticles are optimized in a high throughput manner. In this review, we put an emphasis on a decade of developments of microfluidic systems for engineering nanoparticles in various applications including imaging, biosensing, drug delivery, and theranostic applications.

Synthesis of narrow sized silver nanoparticles in the absence of capping ligands in helical microreactors

Microtubular helical reactors generate secondary flows promoting the synthesis of mono-sized silver nanoparticles in the absence of capping ligands.

Hollow cross-linked enzyme aggregates (h-CLEA) of laccase with high uniformity and activity

Hollow cross-linked enzyme aggregates of laccase (h-CLEA laccase) can be prepared by employing a millifluidic reactor carrying two coaxial laminar flows. In a confluence zone where acetonitrile and an aqueous solution of laccase meet, diffusion of acetonitrile into the aqueous solution gives rise to rapid precipitation of laccase aggregates at the water/acetonitrile interface, as is evidenced by fluorescence images. By controlling the flow rates carefully in the laminar flow regions, h-CLEA laccase around 220±10nm can be obtained, and the size of the h-CLEA laccase increases with increasing flow rates of both solutions. The h-CLEA laccase particles are distinctly different from CLEA laccase prepared in batch processes. The former only consist a crust of cross-linked enzymes (with a hollow core) whereas the latter has a highly porous structure. When the h-CLEA laccase is used as biocatalysts, their activity (0.26U/mg) is comparable to that of free enzymes at neutral pH due to the hollow structure. Moreover, the activity of h-CLEA laccase is higher than that of free laccase at high pH. For example, trypan blue (a dye molecule) can be decolorized completely in the presence of h-CLEA laccase within 270min even at pH 10.0, at which the free enzyme completely loses its activity. Because of their uniform sizes, h-CLEA laccase can be trapped in a membrane for continuous degradation of trypan blue up to 96h without losing any activity. This study shows the superiority of h-CLEA laccase compared to other types of immobilized enzymes.