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.

Droplet-based micromixers are essential units in many microfluidic devices for widespread applications, such as diagnostics and synthesis. The mixers can be either passive or active. When compared to active methods, the passive mixer is widely used because it does not require extra energy input apart from the pump drive. In recent years, several passive droplet-based mixers were developed, where mixing was characterized by both experiments and simulation. A unified physical understanding of both experimental processes and simulation models is beneficial for effectively developing new and efficient mixing techniques. This review covers the state-of-the-art passive droplet-based micromixers in microfluidics, which mainly focuses on three aspects: (1) Mixing parameters and analysis method; (2) Typical mixing element designs and the mixing characters in experiments; and, (3) Comprehensive introduction of numerical models used in microfluidic flow and diffusion.

Microfluidic technology has been highly useful in nanovolume sample preparation, separation, synthesis, purification, detection and assay, which are advantageous in drug development. This review highlights the recent developments and trends in microfluidic applications in two areas of drug development. First, we focus on how microfluidics has been developed as a facile tool for the fabrication of drug carriers including microparticles and nanoparticles. Second, we discuss how microfluidic chips could be used as an independent platform or integrated with other technologies in drug toxicity screening. Challenges and future perspectives of microfluidic applications in drug development have also been provided considering the present technological limitations.

Activated carbon (AC) materials, renowned for their high specific surface area, excellent conductivity, and customizable functional groups, are widely employed as catalyst carriers. However, enhancing the activity of Ru-based catalysts supported on AC (Ru/AC) for ammonia decomposition remains a challenge. In this study, commercial AC was utilized as a substrate, with glucose and urea employed as modifiers. Specifically, the surface of the AC was modified via a hydrothermal pyrolysis method, resulting in the successful post-treatment in situ co-doping of nitrogen (AC-GN). Experimental results revealed that Ru/AC-GN exhibited a hydrogen production rate 46% higher than that of Ru/AC at 475 °C, indicating improved activity and stability. The characterization of AC-GN demonstrated that nitrogen doping primarily occurred on the external surface and macropores of the AC, increasing the nitrogen content in the carrier, particularly pyrrolic nitrogen content, while preserving the original structural and morphological integrity of the AC. The enhanced dispersion of Ru, combined with the improved electronic transmission capabilities and strengthened interactions between the metal and the modified carrier, were identified as pivotal factors contributing to the enhanced low-temperature efficacy of Ru/AC-GN. This paper presents a novel direction for the large-scale preparation of efficient catalysts for ammonia decomposition.

Monodisperse polyvinyl alcohol (PVA) microspheres have been widely used for targeted drug delivery, embolization, and templates. However, the fast and facile fabrication of PVA microspheres with uniform size and internal structure and good sphericity remains a challenge. In this study, the PVA microspheres with uniformity in the size, shape, and internal structure were rapidly fabricated, using single-emulsion droplet templates by an on-chip approach. First, we designed a polydimethylsiloxane (PDMS) microfluidic chip integrated with three functional units, used for the droplet generation, mixing of reagents, and pre-curing of PVA microspheres, respectively. Then, we precisely controlled the generation of PVA aqueous droplets, mixing of reagents, and the gelation rate for the production of high-quality microspheres by adjusting the pH value, flow rate, and the channel structure. The prepared PVA microspheres are characterized with good sphericity, uniform internal structure, and narrow size distribution. The microspheres have good adsorption capacity and recyclability for small-molecule drugs, as demonstrated by the adsorption and desorption of methylene blue (MB). The adsorption behavior is well described by the pseudo-second-order model, and intraparticle diffusion is as fast as the external film diffusion.