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Updated: Nov 14, 2025

Double Emulsion Generation Using a Polydimethylsiloxane PDMS Co-axial Flow Focus Device

Double Emulsion Generation Using a Polydimethylsiloxane PDMS Co-axial Flow Focus Device

Published on: December 25, 2015

Double emulsions with ultrathin shell by microfluidic step-emulsification.

Xinjin Ge¹, Boris Y Rubinstein², Yifeng He¹

¹School of Aerospace Engineering, Beijing Institute of Technology, ZhongGuanCunNan Street #5, 100081, Beijing, China. zhenzhenli@bit.edu.cn.

|March 8, 2021

Summary

This study introduces a novel microfluidic device for single-step production of ultrathin-shelled double emulsions. This method simplifies the process for controlled drug delivery and other biomedical applications.

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Last Updated: Nov 14, 2025

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Area of Science:

Microfluidics
Materials Science
Biomedical Engineering

Background:

Double emulsions with ultrathin shells are crucial for applications like controlled drug release.
Current methods for producing thin-shell double emulsions are complex, requiring multiple steps or intricate channel designs.

Purpose of the Study:

To develop a novel microfluidic device for single-step production of ultrathin-shelled double emulsions.
To control the shell thickness of double emulsions through flow rates.
To establish a theoretical model for predicting emulsification regimes.

Main Methods:

Utilized a microfluidic tri-phasic step-emulsification device with a double-layer PDMS channel.
Investigated oil-in-oil-in-water and water-in-oil-in-water double emulsion formation.
Developed and solved coupled nonlinear differential equations for interface prediction.
Employed finite element method for accurate interface shape analysis.

Main Results:

Successfully produced oil-in-oil-in-water and water-in-oil-in-water double emulsions in a single step.
Achieved controllable shell thicknesses down to 1.4% of the droplet diameter.
Identified four distinct emulsification regimes based on experimental conditions.
Validated a theoretical model against experimental findings with high agreement.

Conclusions:

Demonstrated the feasibility of co-flow step-emulsification for producing double emulsions with ultrathin, controllable shells.
The novel device simplifies the production process compared to existing techniques.
The developed theoretical model accurately predicts emulsification behavior, aiding in process optimization.