Polymeric Microparticles Generated via Confinement-Free Fluid Instability

In-fiber fluid instability can be harnessed to realize scalable microparticles fabrication with tunable sizes and multifunctional characteristics making it competitive in comparison to conventional microparticles fabrication methods. However, since in-fiber fluid instability has to be induced via thermal annealing and the resulting microparticles can only be collected after dissolving the fiber cladding, obtaining contamination-free particles for high-temperature incompatible materials remains great challenge. Herein, confinement-free fluid instability is demonstrated to fabricate polymeric microparticles in a facile manner induced by the ultralow surface energy of the superamphiphobic surface. The polymer solution columns break up into uniform droplets then form spherical particles spontaneously in seconds at ambient temperature. This method can be applied to a variety of polymers spanning an exceptionally wide range of sizes: from 1 mm down to 1 µm. With the aid of microfluidic spinning instrument, a large quantity of microparticles can be obtained, making this method promising for scaling up production. Notably, through simple modification of the feed solution configuration, composite/structured micromaterials can also be produced, including quantum-dots-labeled fluorescent particles, magnetic particles, core-shell particles, microcapsules, and necklace-like microfibers. This method, with general applicability and facile control, is envisioned to have great prospects in the field of polymer microprocessing.