Processing of fast-gelling hydrogel precursors in microfluidics by electrocoalescence of reactive species.

Microscopic hydrogels, also referred to as microgels, find broad application in life and materials science. A well-established technique for fabricating uniform microgels is droplet microfluidics. Here, optimal mixing of hydrogel precursor components is crucial to yield homogeneous microgels with respect to their morphology, mechanics, and distribution of functional moieties. However, when processing premixed polymer precursors that are highly reactive, fast or even instantaneous gelation inside fluid reservoirs or the microchannels of the flow cell commonly occurs, leading to an increase of fluid viscosity over time, and thus exacerbating the intrinsic control over fluid flow rates, droplet and microgel uniformity, which are key selling points of microfluidics in material design. To address these challenges, we utilize microflow cells with integrated electrodes, which enable fast addition and mixing of hydrogel precursors on demand by means of emulsion droplet coalescence. Here, two populations of surfactant-stabilized aqueous droplets - the first containing the material basis of the microgel, and the second containing another gel-forming component (e.g., a crosslinker) are formed at two consecutive microchannel junctions and merged via temporary thin-film instability. Our approach provides the ability to process such hydrogel systems that are otherwise challenging to process into uniform droplets and microgels by conventional droplet microfluidics. To demonstrate its versatility, we fabricate microgels with uniform shape and composition using fast hydrogelation via thiol-Michael addition reaction or non-covalent self-assembly. Furthermore, we elucidate the limitations of electrocoalescence of reactive hydrogel precursors by processing sodium alginate, crosslinked by calcium-induced ionic interactions. For this instantaneous type of hydrogelation, electrocoalescence of alginate and calcium ions does not result in the formation of morphologically isotropic microgels. Instead, it enables the creation of anisotropic microgel morphologies with tunable shape, which have previously only been achieved by selective crosslinking of elaborate higher-order emulsions or by aqueous two-phase systems as microgel templates.

Flexible Materials for High-Resolution 3D Printing of Microfluidic Devices with Integrated Droplet Size Regulation.

We develop resins for high-resolution additive manufacturing of flexible micromaterials via projection microstereolithography (PµSL) screening formulations made from monomer 2-phenoxyethyl acrylate, the cross-linkers Ebecryl 8413, tri(propyleneglycol) diacrylate or 1,3,5-triallyl-1,3,5-triazine-2,4,6(1H,3H,5H)-trione, the photoabsorber Sudan 1, and the photoinitiator diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide. PµSL-printed polymer micromaterials made from this resin library are characterized regarding achievable layer thickness depending on UV exposure energy, and for mechanical as well as optical properties. The best-candidate resin from this screening approach allows for 3D-printing transparent microchannels with a minimum cross section of approximately 35 × 46 µm2, which exhibit proper solvent resistance against water, isopropanol, ethanol, n-hexane, and HFE-7500. The mechanical properties are predestined for 3D-printing microfluidic devices with integrated functional units that require high material flexibility. Exemplarily, we design flexible microchannels for on-demand regulation of microdroplet sizes in microemulsion formation. Our two outlines of integrated droplet regulators operate by injecting defined volumes of air, which deform the droplet-forming microchannel cross-junction, and change the droplet size therein. With this study, we expand the library of functional resins for PµSL printing toward flexible materials with micrometer resolution and provide the basis for further exploration of these materials, e.g., as microstructured cell-culturing substrates with defined mechanics.

Fabrication of Microfluidic Devices for Emulsion Formation by Microstereolithography.

Droplet microfluidics-the art and science of forming droplets-has been revolutionary for high-throughput screening, directed evolution, single-cell sequencing, and material design. However, traditional fabrication techniques for microfluidic devices suffer from several disadvantages, including multistep processing, expensive facilities, and limited three-dimensional (3D) design flexibility. High-resolution additive manufacturing-and in particular, projection micro-stereolithography (PµSL)-provides a promising path for overcoming these drawbacks. Similar to polydimethylsiloxane-based microfluidics 20 years ago, 3D printing methods, such as PµSL, have provided a path toward a new era of microfluidic device design. PµSL greatly simplifies the device fabrication process, especially the access to truly 3D geometries, is cost-effective, and it enables multimaterial processing. In this review, we discuss both the basics and recent innovations in PµSL; the material basis with emphasis on custom-made photopolymer formulations; multimaterial 3D printing; and, 3D-printed microfluidic devices for emulsion formation as our focus application. Our goal is to support researchers in setting up their own PµSL system to fabricate tailor-made microfluidics.

Sulfonated cryogel scaffolds for focal delivery in ex-vivo brain tissue cultures.

The human brain has unique features that are difficult to study in animal models, including the mechanisms underlying neurodevelopmental and psychiatric disorders. Despite recent advances in human primary brain tissue culture systems, the use of these models to elucidate cellular disease mechanisms remains limited. A major reason for this is the lack of tools available to precisely manipulate a specific area of the tissue in a reproducible manner. Here we report an easy-to-use tool for site-specific manipulation of human brain tissue in culture. We show that line-shaped cryogel scaffolds synthesized with precise microscale dimensions allow the targeted delivery of a reagent to a specific region of human brain tissue in culture. 3-sulfopropyl acrylate (SPA) was incorporated into the cryogel network to yield a negative surface charge for the reversible binding of molecular cargo. The fluorescent dyes BODIPY and DiI were used as model cargos to show that placement of dye loaded scaffolds onto brain tissue in culture resulted in controlled delivery without a burst release, and labelling of specific regions without tissue damage. We further show that cryogels can deliver tetrodotoxin to tissue, inhibiting neuronal function in a reversible manner. The robust nature and precise dimensions of the cryogel resulted in a user-friendly and reproducible tool to manipulate primary human tissue cultures. These easy-to-use cryogels offer an innovate approach for more complex manipulations of ex-vivo tissue.

Embedment of Quantum Dots and Biomolecules in a Dipeptide Hydrogel Formed In Situ Using Microfluidics.

As low-molecular-weight hydrogelators, dipeptide hydrogel materials are suited for embedding multiple organic molecules and inorganic nanoparticles. Herein, a simple but precisely controllable method is presented that enables the fabrication of dipeptide-based hydrogels by supramolecular assembly inside microfluidic channels. Water-soluble quantum dots (QDs) as well as premixed porphyrins and a dipeptide in dimethyl sulfoxide (DMSO) were injected into a Y-shaped microfluidic junction. At the DMSO/water interface, the confined fabrication of a dipeptide-based hydrogel was initiated. Thereafter, the as-formed hydrogel flowed along a meandering microchannel in a continuous fashion, gradually completing gelation and QD entrapment. In contrast to hydrogelation in conventional test tubes, microfluidically controlled hydrogelation led to a tailored dipeptide hydrogel regarding material morphology and nanoparticle distribution.

A Non-Cytotoxic Resin for Micro-Stereolithography for Cell Cultures of HUVECs.

Three-dimensional (3D) printing of microfluidic devices continuously replaces conventional fabrication methods. A versatile tool for achieving microscopic feature sizes and short process times is micro-stereolithography (µSL). However, common resins for µSL lack biocompatibility and are cytotoxic. This work focuses on developing new photo-curable resins as a basis for µSL fabrication of polymer materials and surfaces for cell culture. Different acrylate- and methacrylate-based compositions are screened for material characteristics including wettability, surface roughness, and swelling behavior. For further understanding, the impact of photo-absorber and photo-initiator on the cytotoxicity of 3D-printed substrates is studied. Cell culture experiments with human umbilical vein endothelial cells (HUVECs) in standard polystyrene vessels are compared to 3D-printed parts made from our library of homemade resins. Among these, after optimizing material composition and post-processing, we identify selected mixtures of poly(ethylene glycol) diacrylate (PEGDA) and poly(ethylene glycol) methyl ethyl methacrylate (PEGMEMA) as most suitable to allow for fabricating cell culture platforms that retain both the viability and proliferation of HUVECs. Next, our PEGDA/PEGMEMA resins will be further optimized regarding minimal feature size and cell adhesion to fabricate microscopic (microfluidic) cell culture platforms, e.g., for studying vascularization of HUVECs in vitro.

Mechanoresponsive Hydrogel Particles as a Platform for Three-Dimensional Force Sensing.

We introduce a novel concept for mechanosensitive hydrogel microparticles, which translate deformation into changes in fluorescence and can thus function as mechanical probes. The hydrogel particles with controlled polymer network are produced via droplet microfluidics from poly(ethylene glycol) (PEG) precursors. Förster resonance energy transfer donors and acceptors are coupled to the PEG hydrogel network for reporting local deformations as fluorescence shifts. We show that global network deformations, which occur upon drying/rehydration, can be detected via a characteristic fluorescence shift. Combined characterization with confocal laser scanning microscopy and atomic force microscopy (AFM) shows that also local deformation of the particles can be detected. Using AFM, the mechanical properties of the particles can be quantified, which allows linking strain with stress and thus force sensing in a three-dimensional environment. Microfluidic material design allows for precisely varying the size of our hydrogel microparticles as well as their mechanical properties and polymer network structure with regard to the choice of the macromolecular precursors and their functionalization with fluorophores. Thus, concomitant changes in mechanical properties and mechanosensitivity qualify these hydrogel microparticles as an adjustable material platform for force sensing in structural mechanics or cell culturing.