Controlling the morphology of electrospray-generated PLGA microparticles for drug delivery

We developed a well-controlled method to generate PLGA microparticles of different morphologies using the electrospray drying route. By judiciously selecting polymer molecular weight, concentration, and solution flow rate, we can control the order in which polymer entanglements and Coulomb fission occur in the droplets and their relative importance, and subsequently govern the morphology of the resulting polymer particles. We show that spherical, monodisperse particles are generated when sufficiently strong polymer entanglements set in the evaporating droplets before they undergo any Coulomb fission. On the other hand, tailed and elongated particles are obtained if the Coulomb fission occurs first and if the droplets/particles are sufficiently evaporated to freeze in their irregular shape. Strictly spherical particles are unachievable for polymer solutions below a critical concentration, because the onset of Coulomb fission always sets in prior to the development of a sufficiently entangled polymer network. An extension of a simple model, originally used to determine the onset of electrospinning of polymer solutions, adequately predicts when non-spherical particles are produced. We conclude by demonstrating the scale-up of this approach to the synthesis of polymer particles using a compact, microfabricated, multiplexed electrospray system, which would make it suitable for practical applications.