Submicron emulsions could be produced via the tip-streaming process in a flow-focusing microfluidic device. In this article, the stability of the liquid cone and thread for tip-streaming mode could be significantly improved by employing a three-dimensional flow-focusing device, in which the hydraulic resistance was adjusted by modulating the channel heights in the flow focusing area, orifice, downstream and dispersed phase inlet channel. The pressure range for tip-streaming mode was enlarged significantly compared with two-dimensional flow-focusing devices. Therefore, monodisperse emulsions were produced under this tip-streaming mode for as long as 48 hours. Furthermore, we could control the size of emulsion drops by changing the pressure ratio in three-dimensional flow-focusing devices while the liquid cone was easily retracted during the adjustment of pressure ratio in two-dimensional flow-focusing devices. Furthermore, using the uniform submicron emulsion droplets as confining templates, polyethylene glycol (PEG) particles were produced with a narrow size distribution at the sub-micrometre scale. In addition, magnetic nanoparticles were added to the emulsion for magnetic PEG particles, which can respond to magnetic field and would be biocompatible.

The dynamic breakup of emulsion droplets was demonstrated in double-layered microfluidic devices equipped with designed pneumatic actuators. Uniform emulsion droplets, produced by shearing at a T-junction, were broken into smaller droplets when they passed downstream through constrictions formed by a pneumatically actuated valve in the upper control layer. The valve-assisted droplet breakup was significantly affected by the shape and layout of the control valves on the emulsion flow channel. Interestingly, by actuating the pneumatic valve immediately above the T-junction, the sizes of the emulsion droplets were controlled precisely in a programmatic manner that produced arrays of uniform emulsion droplets in various sizes and dynamic patterns.

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A microfluidic approach to prepare photonic microparticles by repeated molding of photocurable colloidal suspension is reported. An elastomeric membrane with negative relieves which vertically separates two microfluidic channels is integrated; bottom channel is used for suspension flow, whereas water-filled top channel is used for pneumatic actuation of the membrane. Upon pressurization of the top channel, membrane is deformed to confine the suspension into its negative relieves, which is then polymerized by UV irradiation, making microparticles with mold shape. The microparticles are released from the mold by relieving the pneumatic pressure and flows through the bottom channel. This one cycle of molding, polymerization, and release can be repeatedly performed in microfluidic device of which pneumatic valves are actuated in a programmed manner. The microparticles exhibit structural colors when the suspension contains high concentration of silica nanoparticles; the nanoparticles form regular arrays and the microparticles reflect specific wavelength of light as a photonic crystals. The silica nanoparticles can be selectively removed to make pronounced structural colors. In addition, the microparticles can be further functionalized by embedding magnetic particles in the matrix of the microparticles, enabling the remote control of rotational motion of microparticles.

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