We present a comprehensive review on the fundamentals of passive and active microfluidic droplet generation.

Surfaces directing fluid flows: Although surfaces can be made to attract or repel liquids using coatings, surface textures with specific curvature can also be used to achieve the same effect. However, fluid transport is usually limited by the specific pattern that only drives flow at the surface itself. Feng et al . created a dual-reentrant surface that has an asymmetric profile so that fluids spread out at the surface and subsurface layers. Furthermore, these surfaces can be designed so that different liquids will naturally steer in opposing directions simply because of their specific interactions with the surface. —MSL

Large-scale and high-efficient water collection of microfibers with long-term durability still remains challenging. Here we present well-controlled, bioinspired spindle-knot microfibers with cavity knots (named cavity-microfiber), precisely fabricated via a simple gas-in-water microfluidic method, to address this challenge. The cavity-microfiber is endowed with unique surface roughness, mechanical strength, and long-term durability due to the design of cavity as well as polymer composition, thus enabling an outstanding performance of water collection. The maximum water volume collected on a single knot is almost 495 times than that of the knot on the cavity-microfiber. Moreover, the spider-web-like networks assembled controllably by cavity-microfibers demonstrate excellent large-scale and high-efficient water collection. To maximize the water-collecting capacity, nodes/intersections should be designed on the topology of the network as many as possible. Our light-weighted yet tough, low-cost microfibers with high efficiency in directional water transportation offers promising opportunities for large-scale water collection in water-deficient areas.

Durability is a long-standing challenge in designing liquid-repellent surfaces. A high-performance omniphobic surface must robustly repel liquids, while maintaining mechanical/chemical stability. However, liquid repellency and mechanical durability are generally mutually exclusive properties for many omniphobic surfaces—improving one performance inevitably results in decreased performance in another. Here we report well-defined porous membranes for durable omniphobic surfaces inspired by the springtail cuticle. The omniphobicity is shown via an amphiphilic material micro-textured with re-entrant surface morphology; the mechanical durability arises from the interconnected microstructures. The innovative fabrication method—termed microfluidic emulsion templating—is facile, cost-effective, scalable and can precisely engineer the structural topographies. The robust omniphobic surface is expected to open up new avenues for diverse applications due to its mechanical and chemical robustness, transparency, reversible Cassie–Wenzel transition, transferability, flexibility and stretchability.

Droplet microfluidics technology is recently a highly interesting platform in material fabrication. Droplets can precisely monitor and control entire material fabrication processes and are superior to conventional bulk techniques. Droplet production is controlled by regulating the channel geometry and flow rates of each fluid. The micro-scale size of droplets results in rapid heat and mass-transfer rates. When used as templates, droplets can be used to develop reproducible and scalable microparticles with tailored sizes, shapes and morphologies, which are difficult to obtain using traditional bulk methods. This technology can revolutionize material processing and application platforms. Generally, microparticle preparation methods involve three steps: (1) the formation of micro-droplets using a microfluidics generator; (2) shaping the droplets in micro-channels; and (3) solidifying the droplets to form microparticles. This review discusses the production of microparticles produced by droplet microfluidics according to their morphological categories, which generally determine their physicochemical properties and applications.