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Nonspherical polymer nano/micro particles: a guide to shape engineering.
Jeremiah James1,2, Emma Leung2, Rong Yang1
1Robert Frederick Smith School of Chemical and Biomolecular Engineering, Cornell University, Ithaca, NY, 14853, USA. ryang@cornell.edu.
Chemical Communications (Cambridge, England)
|April 1, 2026
Summary
Shape-engineered polymer particles offer enhanced performance in applications like drug delivery. This review details over 70 geometries and the fabrication mechanisms, providing a roadmap for creating advanced polymer materials.
Area of Science:
- Materials Science
- Polymer Chemistry
- Nanotechnology
Background:
- Commercial polymer particles are predominantly spherical, limiting performance benefits achievable through shape engineering.
- Shape-engineered polymer particles offer advantages in drug delivery, including longer circulation and targeted penetration.
- A mechanism-centric roadmap linking fabrication to polymer particle morphology has been lacking.
Purpose of the Study:
- To review and categorize diverse polymer particle geometries and their fabrication mechanisms.
- To provide a roadmap connecting polymer particle shape to underlying physicochemical principles.
- To accelerate the design and synthesis of shape-engineered soft materials.
Main Methods:
- Mechanical deformation of spherical particles (stretching, compression, shear).
- Lithographic and template-molding platforms for complex shapes.
- Seeded emulsion polymerization and polymerization under shear for intricate architectures.
- Template-free techniques like plasticization, condensed-droplet polymerization, and electrospraying.
Main Results:
- Cataloged over 70 documented polymer particle geometries.
- Detailed the physicochemical principles governing shape formation via various methods.
- Demonstrated methods for creating diverse shapes from simple deformations to complex architectures like lobed, Janus, and porous particles.
- Highlighted emerging template-free techniques for asymmetric shapes.
Conclusions:
- Fabrication methods are categorized by underlying mechanisms, enabling targeted shape engineering.
- Shape engineering unlocks significant performance gains in polymer micro- and nanoparticles.
- Future directions emphasize green chemistry and scalable processes for societal impact in healthcare, materials, and robotics.
