Controlled viscoelastic particle encapsulation in microfluidic devices

Dimensional analysis meets AI for non-Newtonian droplet generation

Non-Newtonian droplets are used across various applications, including pharmaceuticals, food processing, drug delivery and material science. However, predicting droplet formation using such complex fluids is challenging due to the intricate multiphase interactions between fluids with varying viscosities, elastic properties and geometrical constraints. In this study, we introduce a novel hybrid machine-learning architecture that integrates dimensional analysis with machine learning to predict the flow rates required to generate droplets with specified sizes in systems involving non-Newtonian fluids. Unlike previous approaches, our model is designed to accommodate shear-rate-dependent viscosities and a simple estimate of the elastic properties of the fluids. It provides accurate predictions of the dispersed and continuous phases flow rates for given droplet length, height, and viscosity curves, even when the fluid properties deviate from those used during training. Our model demonstrates strong predictive power, achieving R2 values of up to 0.82 for unseen data. The significance of our work lies in its ability to generalize across a broad range of non-Newtonian systems having different viscosity curves, offering a powerful tool for optimizing droplet generation. This model represents a significant advancement in the application of machine learning to microfluidics, providing new opportunities for efficient experimental design in complex multiphase systems.

A simple guideline for designing droplet microfluidic chips to achieve an improved single (bio)particle encapsulation rate using a stratified flow-assisted particle ordering method

Encapsulation of a single (bio)particle into individual droplets (referred to as single encapsulation) presents tremendous potential for precise biological and chemical reactions at the single (bio)particle level. Previously demonstrated successful strategies often rely on the use of high flow rates, gel, or viscoelastic materials for initial cell ordering prior to encapsulation into droplets, which could potentially challenge the system's operation. We propose to enhance the single encapsulation rate by using a stratified flow structure to focus and pre-order the (bio)particles before encapsulation. The stratified flow structure is formed using two simple aqueous Newtonian fluids with a viscosity contrast, which together serve as the dispersed phase. The single encapsulation rate is influenced by many parameters, including fluid viscosity contrast, geometric conditions, flow conditions and flow rate ratios, and dimensionless numbers such as the capillary number. This study focuses on investigating the influences of these parameters on the focused stream of the stratified flow, which is key for single encapsulation. The results allow the proposal of a simple guideline that can be adopted to design droplet microfluidic chips with an improved single encapsulation rate demanded by a wide range of applications. The guideline was validated by performing the single encapsulation of mouse embryonic stem cells suspended in a gelatin-methacryloyl solution in individual droplets of phosphate buffer saline, achieving a single encapsulation efficiency of up to 70%.

Morphology, repulsion, and ordering of red blood cells in viscoelastic flows under confinement

Red blood cells (RBC), the primary carriers of oxygen in the body, play a crucial role across several biomedical applications, while also being an essential model system of a deformable object in the microfluidics and soft matter fields. However, RBC behavior in viscoelastic liquids, which holds promise in enhancing microfluidic diagnostic applications, remains poorly studied. We here show that using viscoelastic polymer solutions as a suspending carrier causes changes in the clustering and shape of flowing RBC in microfluidic flows when compared to a standard Newtonian suspending liquid. Additionally, when the local RBC concentration increases to a point where hydrodynamic interactions take place, we observe the formation of equally-spaced RBC structures, resembling the viscoelasticity-driven ordered particles observed previously in the literature, thus providing the first experimental evidence of viscoelasticity-driven cell ordering. The observed RBC ordering, unaffected by polymer molecular architecture, persists as long as the surrounding medium exhibits shear-thinning, viscoelastic properties. Complementary numerical simulations reveal that viscoelasticity-induced repulsion between RBCs leads to equidistant structures, with shear-thinning modulating this effect. Our results open the way for the development of new biomedical technologies based on the use of viscoelastic liquids while also clarifying fundamental aspects related to multibody hydrodynamic interactions in viscoelastic microfluidic flows.

A New Approach for On-Chip Production of Biological Microgels Using Photochemical Cross-Linking

Photochemical cross-linking is a key step for manufacturing microgels in numerous applications, including drug delivery, tissue engineering, material production, and wound healing. Existing photochemical cross-linking techniques in microfluidic devices rely on UV curing, which can cause cell and DNA damage. We address this challenge by developing a microfluidic workflow for producing microgels using visible light-driven photochemical cross-linking of aqueous droplets dispersed in a continuous oil phase. We report a proof-of-concept to construct microgels from the protein Bovine Serum Albumin (BSA) with [Ru(bpy)3]2+ mediated cross-linking. By controlling the capillary number of the continuous and dispersed phases, the volumetric flow rate, and the photochemical reaction time within the microfluidic tubing, we demonstrate the construction of protein microgels with controllable and uniform dimensions. Our technique can, in principle, be applied to a wide range of different proteins with biological and responsive properties. This work therefore bridges the gap between hydrogel manufacturing using visible light and microfluidic microgel templating, facilitating numerous biomedical applications.

Emerging Advances in Microfluidic Hydrogel Droplets for Tissue Engineering and STEM Cell Mechanobiology

Hydrogel droplets are biodegradable and biocompatible materials with promising applications in tissue engineering, cell encapsulation, and clinical treatments. They represent a well-controlled microstructure to bridge the spatial divide between two-dimensional cell cultures and three-dimensional tissues, toward the recreation of entire organs. The applications of hydrogel droplets in regenerative medicine require a thorough understanding of microfluidic techniques, the biocompatibility of hydrogel materials, and droplet production and manipulation mechanisms. Although hydrogel droplets were well studied, several emerging advances promise to extend current applications to tissue engineering and beyond. Hydrogel droplets can be designed with high surface-to-volume ratios and a variety of matrix microstructures. Microfluidics provides precise control of the flow patterns required for droplet generation, leading to tight distributions of particle size, shape, matrix, and mechanical properties in the resultant microparticles. This review focuses on recent advances in microfluidic hydrogel droplet generation. First, the theoretical principles of microfluidics, materials used in fabrication, and new 3D fabrication techniques were discussed. Then, the hydrogels used in droplet generation and their cell and tissue engineering applications were reviewed. Finally, droplet generation mechanisms were addressed, such as droplet production, droplet manipulation, and surfactants used to prevent coalescence. Lastly, we propose that microfluidic hydrogel droplets can enable novel shear-related tissue engineering and regeneration studies.

Demand-driven active droplet generation and sorting based on positive pressure-controlled fluid wall

Droplet microfluidics is a rapidly advancing area of microfluidic technology, which offers numerous advantages for cell analysis, such as isolation and accumulation of signals, by confining cells within droplets. However, controlling cell numbers in droplets is challenging due to the uncertainty of random encapsulation which result in many empty droplets. Therefore, more precise control techniques are needed to achieve efficient encapsulation of cells within droplets. Here, an innovative microfluidic droplet manipulation platform had been developed, which employed positive pressure as a stable and controllable driving force for manipulating fluid within chips. The air cylinder, electro-pneumatics proportional valve, and the microfluidic chip were connected through a capillary, which enabled the formation of a fluid wall by creating a difference in hydrodynamic resistance between two fluid streams at the channel junction. Lowering the pressure of the driving oil phase eliminates hydrodynamic resistance and breaks the fluid wall. Regulating the duration of the fluid wall breakage controls the volume of the introduced fluid. Several important droplet microfluidic manipulations were demonstrated on this microfluidic platform, such as sorting of cells/droplets, sorting of droplets co-encapsulated cells and hydrogels, and active generation of droplets encapsulated with cells in a responsive manner. The simple, on-demand microfluidic platform was featured with high stability, good controllability, and compatibility with other droplet microfluidic technologies.

Fluid interfaces laden by force dipoles: towards active matter-driven microfluidic flows

In recent years, nonlinear microfluidics in combination with lab-on-a-chip devices has opened a new avenue for chemical and biomedical applications such as droplet formation and cell sorting. In this article, we integrate ideas from active matter into a microfluidic setting, where two fluid layers with identical densities but different viscosities flow through a microfluidic channel. Most importantly, the fluid interface is laden with active particles that act with dipolar forces on the adjacent fluids and thereby generate flows. We perform lattice-Boltzmann simulations and combine them with phase field dynamics of the interface and an advection-diffusion equation for the density of active particles. We show that only contractile force dipoles can destabilize the flat fluid interface. It develops a viscous finger from which droplets break up. For interfaces with non-zero surface tension, a critical value of activity equal to the surface tension is necessary to trigger the instability. Since activity depends on the density of force dipoles, the interface can develop steady deformation. Lastly, we demonstrate how to control droplet formation using switchable activity.

Viscoelastic Particle Encapsulation Using a Hyaluronic Acid Solution in a T-Junction Microfluidic Device

The encapsulation of particles and cells in droplets is highly relevant in biomedical engineering as well as in material science. So far, however, the majority of the studies in this area have focused on the encapsulation of particles or cells suspended in Newtonian liquids. We here studied the particle encapsulation phenomenon in a T-junction microfluidic device, using a non-Newtonian viscoelastic hyaluronic acid solution in phosphate buffer saline as suspending liquid for the particles. We first studied the non-Newtonian droplet formation mechanism, finding that the data for the normalised droplet length scaled as the Newtonian ones. We then performed viscoelastic encapsulation experiments, where we exploited the fact that particles self-assembled in equally-spaced structures before approaching the encapsulation area, to then identify some experimental conditions for which the single encapsulation efficiency was larger than the stochastic limit predicted by the Poisson statistics.

Effect of wall slip on the viscoelastic particle ordering in a microfluidic channel

The formation of a line of equally spaced particles at the centerline of a microchannel, referred as "particle ordering," is desired in several microfluidic applications. Recent experiments and simulations highlighted the capability of viscoelastic fluids to form a row of particles characterized by a preferential spacing. When dealing with non-Newtonian fluids in microfluidics, the adherence condition of the liquid at the channel wall may be violated and the liquid can slip over the surface, possibly affecting the ordering efficiency. In this work, we investigate the effect of wall slip on the ordering of particles suspended in a viscoelastic liquid by numerical simulations. The dynamics of a triplet of particles in an infinite cylindrical channel is first addressed by solving the fluid and particle governing equations. The relative velocities computed for the three-particle system are used to predict the dynamics of a train of particles flowing in a long microchannel. The distributions of the interparticle spacing evaluated at different slip coefficients, linear particle concentrations, and distances from the channel inlet show that wall slip slows down the self-assembly mechanism. For strong slipping surfaces, no significant change of the initial microstructure is observed at low particle concentrations, whereas strings of particles in contact form at higher concentrations. The detrimental effect of wall slip on viscoelastic ordering suggests care when designing microdevices, especially in case of hydrophobic surfaces that may enhance the slipping phenomenon.

Beating Poisson stochastic particle encapsulation in flow-focusing microfluidic devices using viscoelastic liquids

The encapsulation and co-encapsulation of particles in microfluidic flows is essential in applications related to single-cell analysis and material synthesis. However, the whole encapsulation process is stochastic in nature, and its efficiency is limited by the so-called Poisson limit. We here demonstrate particle encapsulation in microfluidic devices having flow-focusing geometries with efficiency up to 2-fold larger than the stochastic limit imposed by the Poisson statistics. To this aim, we exploited the recently observed phenomenon of particle train formation in viscoelastic liquids, so that particles could approach the encapsulation area with a constant frequency that was subsequently synchronised to the constant frequency of droplet formation. We also developed a simplified expression based on the experimental results that can guide optimal design of the microfluidic encapsulation system. Finally, we report the first experimental evidence of viscoelastic co-encapsulation of particles coming from different streams.

Encapsulation of hygroscopic liquids via polymer precipitation in non-aqueous emulsions

HYPOTHESIS

Encapsulation of ionic liquids (ILs) and phase change materials (PCMs) can overcome limitations associated with bulk materials, e.g., slow mass transfer rates, high viscosities, or susceptibility to external environment. Single step soft-templated encapsulation methods commonly use interfacial polymerization for shell formation, with a multifunctional monomer in the continuous phase and another in the discontinuous phase, and thus do not give pristine core material. We posit that polymer precipitation onto emulsion droplets in non-aqueous emulsions could produce a robust shell without contamination of the core, ideal for the encapsulation of water-sensitive or water-miscible materials.

EXPERIMENTS

Solutions of commodity polymers were added to the continuous phase of non-aqueous Pickering emulsions stabilized by alkylated graphene oxide (GO) nanosheets such that the change in solubility of the polymer led to formation of robust shells and the production of capsules that could be isolated.

FINDINGS

We demonstrate that a polymer precipitation approach can produce capsules with pristine core of the IL 1-ethyl-3-methylimidazolium hexafluorophosphate [Emim][PF₆] or the salt hydrate PCM magnesium nitrate hexahydrate (MNH) and shell of nanosheets and polystyrene, poly(methyl methacrylate), or polyethylene. The capsules are approximately 80 wt% [Emim][PF₆] or >90 wt% MNH, and the core can undergo multiple cycles of solidification and melting without leakage or destruction. This novel, single-step methodology provides a distinct advantage to access capsules with pristine core composition and is amenable to different core and shell, paving the way for tailoring capsule composition for desired applications.