Bulk
hydrogels traditionally used for tissue engineering and drug
delivery have numerous limitations, such as restricted injectability
and a nanoscale porosity that reduces cell invasion and mass transport.
An evolving approach to address these limitations is the fabrication
of hydrogel microparticles (i.e., “microgels”) that
can be assembled into granular hydrogels. There are numerous methods
to fabricate microgels; however, the influence of the fabrication
technique on granular hydrogel properties is unexplored. Herein, we
investigated the influence of three microgel fabrication techniques
(microfluidic devices (MD), batch emulsions (BE), and mechanical fragmentation
by extrusion (EF)) on the resulting granular hydrogel properties (e.g.,
mechanics, porosity, and injectability). Hyaluronic acid (HA) modified
with various reactive groups (i.e., norbornenes (NorHA), pentenoates
(HA-PA), and methacrylates (MeHA)) were used to form microgels with
an average diameter of ∼100 μm. The MD method resulted
in homogeneous spherical microgels, the BE method resulted in heterogeneous
spherical microgels, and the EF method resulted in heterogeneous polygonal
microgels. Across the various reactive groups, microgels fabricated
with the MD and BE methods had lower functional group consumption
when compared to microgels fabricated with the EF method. When microgels
were jammed into granular hydrogels, the storage modulus (G′) of EF granular hydrogels (∼1000–3000
Pa) was consistently an order of magnitude higher than G′ for
MD and BE granular hydrogels (∼50–200 Pa). Void space
was comparable across all groups, although EF granular hydrogels exhibited
an increased number of pores and decreased average pore size when
compared to MD and BE granular hydrogels. Furthermore, granular hydrogel
properties were tuned by varying the amount of cross-linker used during
microgel fabrication. Lastly, granular hydrogels were injectable across
formulations due to their general shear-thinning and self-healing
properties. Taken together, this work thoroughly characterizes the
influence of the microgel fabrication technique on granular hydrogel
properties to inform the design of future systems for biomedical applications.