This paper presents a PDMS emulsification device that is capable of generating water-in-oil-in-water double emulsions in a controlled manner. Specially designed 3D microchannels are utilized to steer the independently driven water- and oil-phase flows (especially to restrict the attachment of the middle oil-phase flow on the channel surfaces), and to break the continuous flows into monodisperse double emulsions. In addition to channel geometries and fluid flow rates, surfactants and osmotic agents are employed to facilitate the breakup process and stabilize the resulting emulsion structures. In the prototype demonstration, two-level SU-8 molds were fabricated to duplicate PDMS microstructures, which were surface treated and bonded irreversibly to form 3D microchannels. Throughout the emulsification trials, dripping was intentionally induced to generate monodisperse double emulsions with single or multiple aqueous droplets inside each oil drop. It is found that the overall and core sizes of the resulting double emulsions could be adjusted independently, mainly by varying the outer and inner fluid flow rates, respectively. As such, the presented double emulsification device could potentially realize the controllability on emulsion structure and size distribution, which is desired for a variety of biological and pharmaceutical applications.

Articular cartilage in synovial joints such as the knee has limited capability to regenerate independently, and most clinical options for focal cartilage repair merely delay total joint replacement. Tissue engineering presents a repair strategy in which an injectable cell-laden scaffold material is used to reconstruct the joint in situ through mechanical stabilisation and cell-mediated regeneration. In this study, we designed and 3D-printed millimetre-scale micro-patterned PEGDA biomaterial microscaffolds which self-assemble through tessellation at a scale relevant for applications in osteochondral cartilage reconstruction. Using simulated chondral lesions in an in vitro model, a series of scaffold designs and viscous delivery solutions were assessed. Hexagonal microscaffolds (750 μm x 300 μm) demonstrated the best coverage of a model cartilage lesion (at 73.3%) when injected with a 1% methyl cellulose solution. When chondrocytes were introduced to the biomaterial via a collagen hydrogel, they successfully engrafted with the printed microscaffolds and survived for at least 14 days in vitro, showing the feasibility of reconstructing stratified cartilaginous tissue using this strategy. Our study demonstrates a promising application of this 4D-printed injectable technique for future clinical applications in osteochondral tissue engineering.