3D printing of monolithic gravity-assisted step-emulsification device for scalable production of high viscosity emulsion droplets

Abstract

Microfluidic technology widely used in generating monodisperse emulsion droplets often suffers from complexity, scalability, applicability to practical fluids, as well as operation instability due to its susceptibility to flow perturbations, low clearance, and depletion of surfactants. Herein, we present a monolithic 3D-printed step-emulsification device (3D-PSD) for scalable and robust production of high viscosity emulsion droplets up to 208.16 mPa s, which cannot be fully addressed using conventional step-emulsification devices. By utilizing stereo-lithography (SLA), 24 triangular nozzles with a pair of 3D void flow distributors are integrated within the 3D-PSD to ensure uniform flow distribution followed by monodisperse droplet formation. The outlets positioned vertically downward enables gravity-assisted clearing to prevent droplet accumulation and thereby maintain size monodispersity. Deposition of silica nanoparticles (SiNP) within the device was also shown to alter the surface wettability from hydrophobic to hydrophilic, enabling the production of both water-in-oil (W/O) as well as oil-in-water (O/W) emulsion droplets, operated at a maximum production rate of up to 50 mL h⁻¹. The utility of the device is further verified through continuous production of biodegradable polycaprolactone (PCL) microparticles using O/W emulsion as templates. We envision that the 3D-PSD presented in this work marks a significant leap in high-throughput production of high viscosity emulsion droplets as well as the particle analogs.