Droplet based microfluidic fabrication of designer microparticles for encapsulation applications.

Developing carriers of active ingredients with pre-determined release kinetics is a main challenge in the field of controlled release. In this work, we fabricate designer microparticles as carriers of active ingredients using droplet microfluidics. We show that monodisperse droplet templates do not necessarily produce monodisperse particles. Magnetic stirring, which is often used to enhance the droplet solidification rate, can promote breakup of the resultant microparticles into fragments; with an increase in the stirring time, microparticles become smaller in average size and more irregular in shape. Thus, the droplet solidification conditions affect the size, size distribution and morphology of the fabricated particles, and these attributes of the microparticles strongly influence their release kinetics. The smaller the average size of the microparticles is, the higher the initial release rate is. The release kinetics of drug carriers is strongly related to their characteristics. The understanding of this relationship enables the fabrication of tailor-designed carriers with a specified release rate, and even programmed release to meet the needs of applications that require a complex release profile of the active ingredients.