Non-spherical particle generation from 4D optofluidic fabrication

Flow lithography for structured microparticles: fundamentals, methods and applications

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

Fabrication and Manipulation of Non-Spherical Particles in Microfluidic Channels: A Review

Non-spherical shape is a general appearance feature for bioparticles. Therefore, a mechanical mechanism study of non-spherical particle migration in a microfluidic chip is essential for more precise isolation of target particles. With the manipulation of non-spherical particles, refined disease detection or medical intervention for human beings will be achievable in the future. In this review, fabrication and manipulation of non-spherical particles are discussed. Firstly, various fabrication methods for non-spherical microparticle are introduced. Then, the active and passive manipulation techniques for non-spherical particles are briefly reviewed, including straight inertial microchannels, secondary flow inertial microchannels and deterministic lateral displacement microchannels with extremely high resolution. Finally, applications of viscoelastic flow are presented which obviously increase the precision of non-spherical particle separation. Although various techniques have been employed to improve the performance of non-spherical particle manipulation, the universal mechanism behind this has not been fully discussed. The aim of this review is to provide a reference for non-spherical particle manipulation study researchers in every detail and inspire thoughts for non-spherical particle focused device design.

Hipster microcarriers: exploring geometrical and topographical cues of non-spherical microcarriers in biomedical applications

Structure and organisation are key aspects of the native tissue environment, which ultimately condition cell fate via a myriad of processes, including the activation of mechanotransduction pathways. By modulating the formation of integrin-mediated adhesions and consequently impacting cell contractility, engineered geometrical and topographical cues may be introduced to activate downstream signalling and ultimately control cell morphology, proliferation, and differentiation. Microcarriers appear as attractive vehicles for cell-based tissue engineering strategies aiming to modulate this 3D environment, but also as vehicles for cell-free applications, given the ease in tuning their chemical and physical properties. In this review, geometry and topography are highlighted as two preponderant features in actively regulating interactions between cells and the extracellular matrix. While most studies focus on the 2D environment, we focus on how the incorporation of these strategies in 3D systems could be beneficial. The techniques applied to design 3D microcarriers with unique geometries and surface topographical cues are covered, as well as specific tissue engineering approaches employing these microcarriers. In fact, successfully achieving a functional histoarchitecture may depend on a combination of fine-tuned geometrically shaped microcarriers presenting intricately tailored topographical cues. Lastly, we pinpoint microcarrier geometry as a key player in cell-free biomaterial-based strategies, and its impact on drug release kinetics, the production of steerable microcarriers to target tumour cells, and as protein or antibody biosensors.

Fabrication of sharp-edged 3D microparticles via folded PDMS microfluidic channels

3D microparticles have promising applications in self-assembly, biomedical engineering, mechanical engineering, etc. The shape of microparticles plays a significant role in their functionalities. Although numerous investigations have been conducted to tailor the shape of microparticles, the diversity is still limited, and it remains a challenge to fabricate 3D microparticles with sharp edges. Here, we present a facile approach that combines a folded PDMS channel and orthogonal projection lithography for shaping sharp-edged 3D microparticles. By adjusting the number and the length of channel sides, both regular and irregular polyhedral cross-sections of the folded channel can be obtained. UV light with diverse patterns is applied vertically as the second shape controlling factor. A variety of 3D microparticles are obtained with sharp edges, which are potential templates for micromachining tools and abrasives. Some sharp-edged microparticles are assembled into 2D and 3D mesoscale structures, which demonstrates their prospective applications in self-assembly, tissue engineering, etc.

Engineered Microgels-Their Manufacturing and Biomedical Applications

Microgels are hydrogel particles with diameters in the micrometer scale that can be fabricated in different shapes and sizes. Microgels are increasingly used for biomedical applications and for biofabrication due to their interesting features, such as injectability, modularity, porosity and tunability in respect to size, shape and mechanical properties. Fabrication methods of microgels are divided into two categories, following a top-down or bottom-up approach. Each approach has its own advantages and disadvantages and requires certain sets of materials and equipments. In this review, we discuss fabrication methods of both top-down and bottom-up approaches and point to their advantages as well as their limitations, with more focus on the bottom-up approaches. In addition, the use of microgels for a variety of biomedical applications will be discussed, including microgels for the delivery of therapeutic agents and microgels as cell carriers for the fabrication of 3D bioprinted cell-laden constructs. Microgels made from well-defined synthetic materials with a focus on rationally designed ultrashort peptides are also discussed, because they have been demonstrated to serve as an attractive alternative to much less defined naturally derived materials. Here, we will emphasize the potential and properties of ultrashort self-assembling peptides related to microgels.

Monodisperse drops templated by 3D-structured microparticles

The ability to create uniform subnanoliter compartments using microfluidic control has enabled new approaches for analysis of single cells and molecules. However, specialized instruments or expertise has been required, slowing the adoption of these cutting-edge applications. Here, we show that three dimensional-structured microparticles with sculpted surface chemistries template uniformly sized aqueous drops when simply mixed with two immiscible fluid phases. In contrast to traditional emulsions, particle-templated drops of a controlled volume occupy a minimum in the interfacial energy of the system, such that a stable monodisperse state results with simple and reproducible formation conditions. We describe techniques to manufacture microscale drop-carrier particles and show that emulsions created with these particles prevent molecular exchange, concentrating reactions within the drops, laying a foundation for sensitive compartmentalized molecular and cell-based assays with minimal instrumentation.

Soft temperature-responsive microgels of complex shape in stop-flow lithography

Stop-flow lithography (SFL) has emerged as a facile high-throughput fabrication method for μm-sized anisometric particles; yet, the fabrication of soft, anisometric microgels has not frequently been addressed in the literature. Furthermore, and to the best of the authors' knowledge, no soft, complex-shaped microgels with temperature-responsive behavior have been fabricated with this technology before. However, such microgels have tremendous potential as building blocks and actuating elements in rapidly developing fields, such as tissue engineering and additive manufacturing of soft polymeric building blocks, bio-hybrid materials, or soft micro-robotics. Given their great potential, we prove in this work that SFL is a viable method for the fabrication of soft, temperature-responsive, and complex-shaped microgels. The microgels, fabricated in this work, consist of poly(N-isopropylacrylamide) (pNIPAm), which is crosslinked with N,N'-methylenebis(acrylamide). The results confirm that the shape of the pNIPAm microgels is determined by the transparency mask, used in SFL. Furthermore, it is shown that, in order to realize stable microgels, a minimum threshold of crosslinker concentration of 2 wt% is required. Above this threshold, the stiffness of pNIPAm microgels can be deliberately altered by adjusting the concentration of the crosslinker. The fabricated pNIPAm microgels show the targeted temperature-responsive behavior. Within this context, temperature-dependent reversible swelling is confirmed, even for fractal-like geometries, such as micro snowflakes. Thus, these microgels provide the targeted unique combination of softness, shape complexity, and temperature responsiveness and increase the freedom of design for actuated building blocks.

FlowSculpt: software for efficient design of inertial flow sculpting devices

Flow sculpting is a powerful method for passive flow control that uses a sequence of bluff-body structures to engineer the structure of inertially flowing microfluidic streams. A variety of cross-sectional flow shapes can be created through this method, offering a new platform for flow manipulation or material fabrication useful in bioengineering, manufacturing, and chemistry applications. However, the inverse problem in flow sculpting - designing a device that produces a target fluid flow shape - remains challenging due to the complex, diverse, and enormous design space. Solutions to the inverse problem have been constrained to single-material fluid streams that are shaped into top-bottom symmetric shapes due to the bluff-body structures available in current libraries (pillars) that span the height of the channel. In this work, we introduce multi-material design and symmetry-breaking flow deformations enabled by half-height pillars, presented within an extremely fast simulation method for flow sculpting yielding a 34-fold reduction in runtime. The framework is deployed freely as a cross-platform application called "FlowSculpt". We detail its implementation and usage, and discuss the addition of enhanced search operations, which enable users to more easily design flow shapes that replicate their input drawings. With FlowSculpt, the microfluidics community can now quickly design flow shaping microfluidic devices on modest hardware, and easily integrate these complex physics into their research toolkit.

Designable 3D Microshapes Fabricated at the Intersection of Structured Flow and Optical Fields

3D structures with complex geometric features at the microscale, such as microparticles and microfibers, have promising applications in biomedical engineering, self-assembly, and photonics. Fabrication of complex 3D microshapes at scale poses a unique challenge; high-resolution methods such as two-photon-polymerization have print speeds too low for high-throughput production, while top-down approaches for bulk processing using microfabricated template molds have limited control of microstructure geometries over multiple axes. Here, a method for microshape fabrication is presented that combines a thermally drawn transparent fiber template with a masked UV-photopolymerization approach to enable biaxial control of microshape fabrication. Using this approach, high-resolution production of complex microshapes not producible using alternative methods is demonstrated, such as octahedrons, dreidels, and axially asymmetric fibers, at throughputs as high as 825 structures/minute. Finally, the fiber template is functionalized with conductive electrodes to enable hierarchical subparticle localization using dielectrophoretic forces.

DIY 3D Microparticle Generation from Next Generation Optofluidic Fabrication

Complex-shaped microparticles can enhance applications in drug delivery, tissue engineering, and structural materials, although techniques to fabricate these particles remain limited. A microfluidics-based process called optofluidic fabrication that utilizes inertial flows and ultraviolet polymerization has shown great potential for creating highly 3D-shaped particles in a high-throughput manner, but the particle dimensions are mainly at the millimeter scale. Here, a next generation optofluidic fabrication process is presented that utilizes on-the-fly fabricated multiscale fluidic channels producing customized sub-100 µm 3D-shaped microparticles. This flexible design scheme offers a user-friendly platform for rapid prototyping of new 3D particle shapes, providing greater potential for creating impactful engineered microparticles.

High-Throughput Optofluidic Acquisition of Microdroplets in Microfluidic Systems

Droplet optofluidics technology aims at manipulating the tiny volume of fluids confined in micro-droplets with light, while exploiting their interaction to create "digital" micro-systems with highly significant scientific and technological interests. Manipulating droplets with light is particularly attractive since the latter provides wavelength and intensity tunability, as well as high temporal and spatial resolution. In this review study, we focus mainly on recent methods developed in order to monitor real-time analysis of droplet size and size distribution, active merging of microdroplets using light, or to use microdroplets as optical probes.

3D shape evolution of microparticles and 3D enabled applications using non-uniform UV flow lithography (NUFL)

The generation of microparticles with non-spherical morphologies has generated extensive interest because of their enhanced physical properties that can increase their performance in a wide variety of clinical and industrial applications. A flow lithographic technique based on stop flow lithography (SFL) recently showed the ability to fabricate particles with 3D shapes via manipulation of the UV intensity profile in a simple 2D microfluidic channel. Here, we further explore this flow lithographic method, called non-uniform flow lithography (NUFL), to investigate the 3D-shape tuning ability for the generation of 3D magnetic microparticles and their potential applications. We characterize the morphological microparticle shape change through variation of polymerization objective, UV intensity, and solution opacity. We also couple the particles' intrinsic anisotropic magnetic properties with an external magnetic field to create chains of bullet- and bell-shaped particles and a valve-like micromachine. In addition, in contrast to other complex and multi-step methodologies, NUFL shows a simple route for the facile creation of 3D microstructure platforms such as microneedles with fully modifiable tip morphology. This method presents intriguing possibilities for growing research within 3D microstructure assembly, micromachine systems and minimally invasive medical interventions.

Deep Learning for Flow Sculpting: Insights into Efficient Learning using Scientific Simulation Data

A new technique for shaping microfluid flow, known as flow sculpting, offers an unprecedented level of passive fluid flow control, with potential breakthrough applications in advancing manufacturing, biology, and chemistry research at the microscale. However, efficiently solving the inverse problem of designing a flow sculpting device for a desired fluid flow shape remains a challenge. Current approaches struggle with the many-to-one design space, requiring substantial user interaction and the necessity of building intuition, all of which are time and resource intensive. Deep learning has emerged as an efficient function approximation technique for high-dimensional spaces, and presents a fast solution to the inverse problem, yet the science of its implementation in similarly defined problems remains largely unexplored. We propose that deep learning methods can completely outpace current approaches for scientific inverse problems while delivering comparable designs. To this end, we show how intelligent sampling of the design space inputs can make deep learning methods more competitive in accuracy, while illustrating their generalization capability to out-of-sample predictions.