Development of a continuous-flow microfluidic process for microsphere production

IF 2.7 4区材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials Letters Pub Date : 2025-10-02 DOI:10.1016/j.matlet.2025.139599

Keerthi Renganathan , Ratnesh Jain , Darshan Chheda , Chandrakanth Gadipelly , Ganesh Gaikwad

引用次数: 0

Abstract

A continuous-flow microfluidic process was developed to synthesize PLGA microspheres with controlled size and distribution. An automated platform (nanomake-L™) with a split-and-recombine microfluidic chip synthesized microspheres via double-emulsion solvent evaporation, overcoming scalability limitations of droplet-based systems. The device achieved 91.87 % mixing efficiency at 40 mL min⁻¹ and 99.07 % volume accuracy. A definitive screening design identified solvent, emulsion ratio, and flow rate as the most significant factors. Microspheres sizes ranged from 9.90 to 85.80 μm (average: 46.88 ± 2.2 μm). SEM confirmed smooth, spherical microspheres, with 63.02 ± 3.28 % yield. This study demonstrates continuous microfluidics for automated, high-throughput, and consistent microsphere production, highlighting the platform's potential for scalable pharmaceutical manufacturing.

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微球生产连续流微流控工艺的开发

采用连续流微流控工艺合成了尺寸和分布可控的PLGA微球。一个自动化平台（nanomake-L™）与一个分裂和重组的微流控芯片通过双乳液溶剂蒸发合成微球，克服了基于液滴系统的可扩展性限制。该装置在40 mL min - 1下的混合效率为91.87%，体积精度为99.07%。确定的筛选设计确定溶剂、乳液比和流速是最重要的因素。微球尺寸范围为9.90 ~ 85.80 μm（平均46.88±2.2 μm）。SEM证实微球光滑，呈球形，收率为63.02±3.28%。该研究展示了连续微流体用于自动化、高通量和一致的微球生产，突出了该平台在可扩展制药制造方面的潜力。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Materials Letters 工程技术-材料科学：综合

CiteScore

5.60

自引率

3.30%

发文量

1948

审稿时长

50 days

期刊介绍： Materials Letters has an open access mirror journal Materials Letters: X, sharing the same aims and scope, editorial team, submission system and rigorous peer review. Materials Letters is dedicated to publishing novel, cutting edge reports of broad interest to the materials community. The journal provides a forum for materials scientists and engineers, physicists, and chemists to rapidly communicate on the most important topics in the field of materials. Contributions include, but are not limited to, a variety of topics such as: • Materials - Metals and alloys, amorphous solids, ceramics, composites, polymers, semiconductors • Applications - Structural, opto-electronic, magnetic, medical, MEMS, sensors, smart • Characterization - Analytical, microscopy, scanning probes, nanoscopic, optical, electrical, magnetic, acoustic, spectroscopic, diffraction • Novel Materials - Micro and nanostructures (nanowires, nanotubes, nanoparticles), nanocomposites, thin films, superlattices, quantum dots. • Processing - Crystal growth, thin film processing, sol-gel processing, mechanical processing, assembly, nanocrystalline processing. • Properties - Mechanical, magnetic, optical, electrical, ferroelectric, thermal, interfacial, transport, thermodynamic • Synthesis - Quenching, solid state, solidification, solution synthesis, vapor deposition, high pressure, explosive