Controlled encapsulation is important in pharmaceutics, agriculture, food products, and in emerging materials applications. Microfluidics offers a compelling approach to create controlled emulsions and microcapsules for these applications, but upscaling of this technology for the robust encapsulation of chemically diverse active ingredients is not yet demonstrated. Here, it is shown that microfluidic step emulsification can be exploited in upscaled glass devices to robustly produce monodisperse double emulsions and functional microcapsules in tandem at high throughput rates. The effect of geometrical parameters of the devices and the operating flow rates on the morphology, dimensions, and structure of monodisperse double emulsions is investigated and quantified using simple quantitative models. Using such double emulsions as templates, mechanoresponsive microcapsules that can be embedded in a soft matrix to generate damage‐reporting polymer parts that change color in areas subjected to excessive mechanical loads are created. Thanks to the chemical versatility and mechanical robustness of glass, this platform should enable the high‐throughput encapsulation of a wide variety of chemicals while providing the exquisite control achievable through microfluidics.
Materials for thermal management of buildings offer an attractive approach to reduce energy demands and carbon emissions in the infrastructure sector, but many of the state‐of‐the‐art insulators are still expensive, flammable, or difficult to recycle. Here, a 3D printing process is developed and studied to create hierarchical porous ceramics for thermal insulation and passive cooling using recyclable and widely available clay as raw material. Inks comprising particle‐stabilized foams are employed as a template for the generation of the hierarchical porosity. Using foams with optimized rheological properties, the printing parameters and sintering conditions required for the manufacturing of hierarchical porous ceramics via Direct Ink Writing are established. The sintering temperature is found to strongly affect the size distribution of micropores, thus controlling the mechanical, thermal, and evaporative cooling properties of sintered printed structures. By combining suspension‐ and foam‐based inks in a multimaterial printing approach, inexpensive and recyclable clay‐based bricks are manufactured with structural, thermal insulating, and passive cooling capabilities.
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