Search Results (105)

Oral delivery of hydrophobic compounds remains challenging due to their poor aqueous solubility and the potential toxicity associated with conventional surfactant-based emulsions. To address these issues, we present a surfactant-free encapsulation strategy using electrosprayed alginate hydrogel beads for the stable and controlled delivery of hydrophobic oils. Hydrophobic compounds were dispersed in high-viscosity alginate solutions without surfactants via ultrasonication, forming kinetically stable oil-in-water dispersions. These mixtures were electrosprayed into calcium chloride baths, yielding monodisperse hydrogel beads. Higher alginate concentrations improved droplet sphericity and suppressed phase separation by enhancing matrix viscosity. The resulting beads exhibited stimuli-responsive degradation and controlled release behavior in response to physiological ionic strength. Dense alginate networks delayed ion exchange and prolonged structural integrity, while elevated external ionic conditions triggered rapid disintegration and immediate payload release. This simple and scalable system offers a biocompatible platform for the oral delivery of lipophilic active compounds without the need for surfactants or complex fabrication steps. Full article

Phase-change microcapsules offer significant advantages for thermal energy storage and regulation. However, conventional mechanical agitation fabrication methods encounter difficulties in achieving monodispersity, precise size control, and structural uniformity. Droplet microfluidics emerges as a promising alternative, enabling controllable production of microcapsules with tunable sizes (1–1000 μm), programmable core–shell configurations, and high encapsulation efficiency. This review comprehensively summarizes recent advances in microfluidic strategies for phase-change microcapsules fabricating, including single encapsulation, multi-core encapsulation, and high-throughput parallelization and their applications in solar energy storage, building thermal regulation, electronics cooling, and smart textiles. The review highlights key challenges for future advancement which will unlock the full potential of microfluidics-engineered phase-change microcapsules in next-generation thermal energy technologies. Full article

This study proposes a simple yet versatile microfluidic strategy for fabricating monodisperse alginate hydrogel microspheres using a symmetric flow-focusing device. The system integrates three key innovations: (1) Cost-effective mold fabrication: A paper-based positive master replaces conventional SU-8 photoresist, significantly simplifying device prototyping. (2) Surfactant-free droplet generation: Alginate hydrogel droplets are formed at the first flow-focusing junction without requiring interfacial stabilizers. (3) In situ solidification with coalescence suppression: Acetic acid-infused corn oil is introduced at the adjacent junction, simultaneously triggering ionic crosslinking of alginate via pH reduction while preventing droplet aggregation. Notably, the hydrogel microspheres can be efficiently harvested through oscillatory aqueous phase separation, removing post-fabrication washing steps (typically 6–8 cycles for surfactant and oil removal). This integrated approach demonstrates exceptional advantages in fabrication simplicity, process scalability, and operational robustness for high-throughput hydrogel microsphere production. Full article

Lipids are often ingested via oil-in-water (O/W) emulsions, where interfacial properties and droplet size influence their digestibility. In this study, a bimodal O/W emulsion, termed Food Emulsion Blend (FEB), was prepared by mixing two monodisperse emulsions of different droplet sizes and compositions. The influence of droplet size and emulsifier type on in vitro digestion was evaluated. Soybean oil was used as the dispersed phase, and monodisperse emulsions were prepared via premix membrane emulsification using membranes with pore sizes of 1, 10, and 50 µm. Two selected emulsions were mixed in equal proportions to form FEB. The emulsifiers included 1.0% (w/w) Tween 20 (TW) or 0.5% (w/w) Tween 20 and 0.5% (w/w) citrus pectin (TWCP). The $d_{\mathrm{4,3}}$ values of the emulsions stabilized by TW and TWCP ranged from 1.05 to 51.99 µm and from 1.19 to 46.94 µm, respectively. In vitro digestion revealed that all FEB samples retained bimodal size distributions post-gastric digestion. Free fatty acid release correlated strongly with the initial total droplet surface area for the TW- and TWCP-stabilized FEBs (R² > 0.8). These results suggest that FEB allows for the precise control of lipid release, offering potential applications in food formulation. Full article

Step emulsification (SE) is renowned for its robustness in generating monodisperse emulsion droplets at arrayed nozzles. However, few studies have explored poly(dimethylsiloxane) (PDMS)-based SE devices for producing monodisperse oil-in-water (O/W) droplets and polymeric microspheres with diameters below 20 µm—materials with broad applicability. In this study, we present a PDMS-based microfluidic SE device designed to achieve this goal. Two devices with 264 nozzles each were fabricated, featuring straight and triangular nozzle configurations, both with a height of 4 µm and a minimum width of 10 µm. The devices were rendered hydrophilic via oxygen plasma treatment. A photocurable acrylate monomer served as the dispersed phase, while an aqueous polyvinyl alcohol solution acted as the continuous phase. The straight nozzles produced polydisperse droplets with diameters exceeding 30 µm and coefficient-of-variation (CV) values above 10%. In contrast, the triangular nozzles, with an opening width of 38 µm, consistently generated monodisperse droplets with diameters below 20 µm, CVs below 4%, and a maximum throughput of 0.5 mL h⁻¹. Off-chip photopolymerization of these droplets yielded monodisperse acrylic microspheres. The low-cost, disposable, and scalable PDMS-based SE device offers significant potential for applications spanning from laboratory-scale research to industrial-scale particle manufacturing. Full article

Traditional methods of weed control during field management often result in herbicide waste. Precision herbicide application is crucial in agricultural production. This study presents a monodisperse droplet-generation system designed for precision herbicide application, capable of generating monodisperse droplets induced by an electric field. Droplet-generation experiments were conducted to investigate the effects of capillary tube outlet shape, liquid flow rate, and capillary tube size on the generation of charged droplets. A droplet diameter prediction model was established based on the system parameters. Experimental results indicated that as the applied voltage increased, the droplet diameter decreased, and the droplet-generation patterns transitioned sequentially from dripping, micro-dripping, to unstable dripping modes. In a weak electric field, capillaries with beveled outlets produced smaller droplets with more stable diameter distributions compared to those with blunt outlets. In a strong electric field, the smallest droplet diameter from blunt capillaries was 138.2 μm, whereas from beveled capillaries it was 198.7 μm. Within the design parameter range, droplet diameter was basically positively correlated with liquid flow rate and capillary tube size. By controlling the applied voltage, liquid flow rate, and capillary tube size, stable droplet generation could be achieved within a diameter range of 198.7–2520.8 μm, and the coefficient of variation of droplet diameter under the same working conditions was generally less than 6%. The monodisperse droplet-generation system developed in this study can effectively reduce herbicide usage and improve application efficiency. Full article

Directed evolution is a powerful technique for creating biomolecules such as proteins and nucleic acids with tailor-made properties for therapeutic and industrial applications by mimicking the natural evolution processes in the laboratory. Droplet microfluidics improved classical directed evolution by enabling time-consuming and laborious steps in this iterative process to be performed within monodispersed droplets in a highly controlled and automated manner. Droplet microfluidic chips can generate, manipulate, and sort individual droplets at kilohertz rates in a user-defined microchannel geometry, allowing new strategies for high-throughput screening and evolution of biomolecules. In this review, we discuss directed evolution studies in which droplet-based microfluidic systems were used to screen and improve the functional properties of biomolecules. We provide a systematic overview of basic on-chip fluidic operations, including reagent mixing by merging continuous fluid streams and droplet pairs, reagent addition by picoinjection, droplet generation, droplet incubation in delay lines, chambers and hydrodynamic traps, and droplet sorting techniques. Various microfluidic strategies for directed evolution using single and multiple emulsions and biomimetic materials (giant lipid vesicles, microgels, and microcapsules) are highlighted. Completely cell-free microfluidic-assisted in vitro compartmentalization methods that eliminate the need to clone DNA into cells after each round of mutagenesis are also presented. Full article

Step emulsification is a key technique for achieving scalable production of monodisperse emulsion droplets owing to its resilience to flow fluctuations. However, the persistent issue of satellite droplets, an inherent byproduct of main droplets, poses challenges for achieving truly uniform product sizes. In a previous study, we introduced a module with step-emulsifier nozzles upstream and deterministic lateral displacement (DLD) micropillar arrays downstream to generate satellite-free droplets at a low throughput. In this study, we demonstrate an upscaled parallelized setup with ten modules that were designed to produce satellite-free droplets. Each module integrated 100 step-emulsification nozzles in the upstream region with DLD micropillar arrays downstream. We conducted 3D flow simulations to ensure homogeneous distribution of the input fluids. Uniformly supplying an aqueous polyvinyl alcohol solution and an acrylate monomer as continuous and dispersed phases into the ten modules, the nozzles in each module exhibited a production rate of 539.5 ± 28.6 drop/s (n = 10). We successfully isolated the main droplets with a mean diameter of 66 μm and a coefficient of variation of 3.1% from satellite droplets with a mean diameter of 3 μm. The total throughput was 3.0 mL/h. The high yield and contamination-free features of our approach are promising for diverse industrial applications. Full article

Microfluidics offers a highly controlled and reproducible route to synthesize lipid vesicles. In recent years, several microfluidic approaches have been introduced for this purpose, but double emulsions, such as Water-in-Oil-in-Water (W/O/W) droplets, are preferable to produce giant vesicles that are able to maximize material encapsulation. Flow focusing (FF) is a technique used to generate double emulsion droplets with high monodispersity, a controllable size, and good robustness. Many researchers use polydimethylsiloxane as a substrate material to fabricate microdroplet generators, but it has some limitations due to its hydrophobicity, incompatibility with organic solvents, and the molecular adsorption on the microchannel walls. Thus, specific surface modification and functionalization steps, which are uncomfortable to perform in closed microchannels, are required to overcome these shortcomings. Here, we propose glass as a material to produce a chip with a six-inlet junction geometry. The peculiar geometry and the glass physicochemical properties allow for W/O/W droplet formation without introducing microchannel wall functionalization and using a variety of reagents and organic solvents. The robust glass chip can be easily cleaned and used repeatedly, bringing advantages in terms of cost and reproducibility in emulsion preparation. Full article

Emulsion formulations should be monodispersed in terms of their stability. Therefore, there is a need for a device that can classify droplets of the desired size from polydispersed emulsions in a fluidized bed manufacturing system. In the previous study, we evaluated the fabrication of a droplet manipulation device using acoustic radiation forces through simulation using the finite element method. In this study, particle manipulation experiments using 1, 6, and 10 µm polystyrene particles were first estimated and evaluated in comparison with their theoretical particle behavior. Based on the results we obtained, the driving conditions and droplet behavior were derived, and the droplet manipulation device using ultrasonic waves to shrink monodisperse emulsions was evaluated. As a result, the droplet classification effect in the microchannel was confirmed to be consistent with the droplet behavior prediction, and the microchannel structure with a constriction component improved its classification effect. Full article

Microdroplets have been widely used in different fields due to their unique properties, such as compartmentalization, single-molecule sensitivity, chemical and biological compatibility, and high throughput. Compared to intricate and labor-intensive microfluidic techniques, the centrifuge-based method is more convenient and cost-effective for generating droplets. In this study, we developed a handy injection molding based method to readily produce monodisperse droplets by centrifugation. Briefly, we used two three-dimensional (3D) printed master molds with internal cavities to forge two coupled sub-molds by injecting polydimethylsiloxane (PDMS) and casted these two PDMS sub-molds into a nested structure that clamps the micro-channel array (MiCA) by injecting polyurethane resin. This method enables the generation of various sizes of monodispersed microdroplets by centrifugation with proper parameters within 10 min. To assess the performance of this method, homogeneous fluorescent hydrogel microspheres were generated and droplet digital polymerase chain reaction (ddPCR) was carried out. Overall, this method offers high-throughput droplet generation, reduces costs compared to other methods, and is user-friendly. Full article

Accidental crankcase explosions in marine diesel engines are presumably caused by the inflammation of lubricating oil in air followed by flame propagation and pressure buildup. This manuscript deals with the numerical simulation of internal unvented and vented crankcase explosions of lubricating oil mist using the 3D CFD approach for two-phase turbulent reactive flow with finite-rate turbulent/molecular mixing and chemistry. The lubricating oil mist was treated as either monodispersed with a droplet size of 60 μm or polydispersed with a trimodal droplet size distribution (10 $\mathsf{\mu }$m (10 wt%), 250 $\mathsf{\mu }$m (10 wt%), and 500 $\mathsf{\mu }$m (80 wt%)). The mist was partly pre-evaporated with pre-evaporation degrees of 60%, 70%, and 80%. As an example, a typical low-speed two-stroke six-cylinder marine diesel engine was considered. Four possible accidental ignition sites were considered in different linked segments of the crankcase, namely the leakage of hot blow-by gases through the faulty stuffing box, a hot spot on the crankpin bearing, electrostatic discharge in the open space at the A-frame, and a hot spot on the main bearing. Calculations show that the most important parameter affecting the dynamics of crankcase explosion is the pre-evaporation degree of the oil mist, whereas the oil droplet size distribution plays a minor role. The most severe unvented explosion was caused by the hot spot ignition of the oil mist on the main bearing and flame breaking through the windows connecting the crankcase segments. The predicted maximum rate of pressure rise in the crankcase attained 0.6–0.7 bar/s, whereas the apparent turbulent burning velocity attained 7–8 m/s. The rate of heat release attained a value of 13 MW. Explosion venting caused the rate of pressure rise to decrease and become negative. However, vent opening does not lead to an immediate pressure drop in the crankcase: the pressure keeps growing for a certain time and attains a maximum value that can be a factor of 2 higher than the vent opening pressure. Full article

Using devices with microfluidic channels can allow for precise control over liquids flowing through them. Merging flows of immiscible liquids can create emulsions with highly monodispersed microdroplets within a carrier liquid, which are ideal for miniaturised reaction vessels which can be generated with a high throughput of tens of thousands of droplets per second. Control of the size and composition of these droplets is generally performed by controlling the pumping system pushing the liquids into the device; however, this is an indirect manipulation and inadequate if absolute precision is required in the size or composition of the droplets. In this work, we extend the previous development of image-based closed-loop feedback control over microdroplet generation to allow for the control of not only the size of droplets but also the composition by merging two aqueous flows. The feedback allows direct control over the desired parameters of volume and ratio of the two components over a wide range of ratios and outperforms current techniques in terms of monodispersity in volume and composition. This technique is ideal for situations where precise control over droplets is critical, or where a library of droplets of different concentrations but the same volume is required. Full article

Monodispersed polyethylene glycol diacrylate (PEGDA)/acrylic acid (AA) microgels with a tuneable negative charge and macroporous internal structure have been produced using a Lego-inspired droplet microfluidic device. The surface charge of microgels was controlled by changing the content of AA in the monomer mixture from zero (for noncharged PEGDA beads) to 4 wt%. The macroporosity of the polymer matrix was introduced by adding 20 wt% of 600-MW polyethylene glycol (PEG) as a porogen material into the monomer mixture. The porogen was successfully leached out with acetone after UV-crosslinking, which resulted in micron-sized cylindrical pores with crater-like morphology, uniformly arranged on the microgel surface. Negatively charged PEGDA/AA beads showed improved adsorption capacity towards positively charged organic dyes (methylene blue and rhodamine B) compared to neutral PEGDA beads and high repulsion of negatively charged dye molecules (methyl orange and congo red). Macroporous microgels showed better adsorption properties than nonporous beads, with a maximum adsorption capacity towards methylene blue of 45 mg/g for macroporous PEGDA/AA microgels at pH 8.6, as compared to 23 mg/g for nonporous PEGDA/AA microgels at the same pH. More than 98% of Cu(II) ions were removed from 50 ppm solution at pH 6.7 using 2.7 mg/mL of macroporous PEGDA/AA microgel. The adsorption of cationic species was significantly improved when pH was increased from 3 to 9 due to a higher degree of ionization of AA monomeric units in the polymer network. The synthesized copolymer beads can be used in drug delivery to achieve improved loading capacity of positively charged therapeutic agents and in tissue engineering, where a negative charge of scaffolds coupled with porous structure can help to achieve improved permeability of high-molecular-weight metabolites and nutrients, and anti-fouling activity against negatively charged species. Full article

The paper presents the results of studying the effects of droplet diameters on the NACA0012 airfoil ice accretion, which have been obtained in the 3D numerical simulation of icing. To simulate the motion of water droplets as a multiphase medium, the Eulerian approach is used, which assumes that water droplets have spherical shapes, do not undergo deformation and breakup, do not interact with each other, and that coalescence/fragmentation of droplets does not take place. Both monodisperse (of the same size) and polydisperse (of various sizes) droplets are considered; they are represented by the spectral Langmuir distributions. These spectral distributions take into account the polydisperse nature of droplets and provide a higher efficiency in predicting ice shapes. The obtained ice shapes on an airfoil are compared with the available experimental and calculated data. It should be noted according to the simulation results that the use of the standard size of droplet diameter equal to 20 μm does not allow for obtaining correct shapes of ice on the leading edge of the wing profile not at all temperature regimes. For temperatures from −20 °C to −10 °C, there is a noticeable difference compared to the experimental data. At the same time, for this temperature range, the use of the Langmuir spectral distribution of droplet diameters relative to 15 μm provides a better agreement of the formed ice forms with the experiment. Full article