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.

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.

Advances in tissue engineering (TE) have revealed that porosity architectures, such as pore shape, pore size and pore interconnectivity are the key morphological properties of scaffolds. Well-ordered porous polymer scaffolds, which have uniform pore size, regular geometric shape, high porosity and good pore interconnectivity, facilitate the loading and distribution of active biomolecules, as well as cell adhesion, proliferation and migration. However, these are difficult to prepare by traditional methods and the existing well-ordered porous scaffold preparation methods require expensive experimental equipment or cumbersome preparation steps. Generally, droplet-based microfluidics, which generates and manipulates discrete droplets through immiscible multiphase flows inside microchannels, has emerged as a versatile tool for generation of well-ordered porous materials. This short review details this novel method and the latest developments in well-ordered porous scaffold preparation via microfluidic technology. The pore structure and properties of microfluidic scaffolds are discussed in depth, laying the foundation for further research and application in TE. Furthermore, we outline the bottlenecks and future developments in this particular field, and a brief outlook on the future development of microfluidic technique for scaffold fabrication is presented.

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.

The impact of liquid drops on superhydrophobic solid surfaces is ubiquitous and of practical importance in many industrial processes. Here, we study the impingement of droplets on superhydrophobic surfaces with a macroscopic dimple structure, during which the droplet exhibits asymmetric jetting. Systematic experimental investigations and numerical simulations provide insight into the dynamics and underlying mechanisms of the observed phenomenon. The observation is a result of the interaction between the spreading droplet and the dimple. An upward internal flow is induced by the dimple, which is then superimposed on the horizontal flow inside the spreading droplet. As such, an inclined jet is issued asymmetrically into the air. This work would be conducive to the development of an open-space microfluidic platform for droplet manipulation and generation.

Vascular stenosis is always associated with hemodynamic changes, especially shear stress alterations. Herein, bi-conical shaped microvessels were developed through flexibly and precisely controlled templated methods for hydrogel blood-vessel-like microchip. The blood-vessel-like microvessels demonstrated tunable dimensions, perfusable ability, and good cytocompatibility. The microchips showed blood-vessel-like lumens through fine embeddedness of human umbilical vein endothelial cells (HUVECs) on the interior surface of hydrogel microchannels, which closely reproduced the morphology and functions of human blood vessels. In the gradual narrowing region of bi-conical shape, fluid flow generated wall shear stress, which caused cell morphology variations. Wall shear rates at the gradual narrowing region were simulated by FLUENT software. The results showed that our microchannels qualified for performance as a vascular stenosis-like model in evaluating blood hydrodynamics. In general, our blood-vessel-on-a-chip could offer potential applications in the prevention, diagnosis, and therapy of arterial thrombosis.