Three-dimensional coaxial multi-nozzle device for high-rate microsphere generation

To address the need for production of a large number of microspheres for use in various fields such as tissue engineering, we developed a 3D coaxial multi-nozzle flow focusing device fabricated via a simple 3D printing method that demonstrates a high rate of microsphere production per nozzle. This device has six coaxial microscale nozzles that produce hydrogel microspheres. Two individual parts-the inlet and nozzle-can be made separately by a 3D printer and bonded together using uncured photo-curable resin as glue. The dimensions of the microspheres are between 100 and 1200 mu m. They are produced by adjusting the flow rate ratio between the dispersed and continuous media. A flow rate ratio of 180 demonstrated the highest microsphere production rate of 2.12e+5 microspheres per second (0.25 mL min(-1)). This microsphere production rate per nozzle is four times higher than that of currently available devices.