Precision Microspheres Enabled by Interfacial Engineering from Controlled Fabrication to Emerging Applications

Microspheres are key building blocks for high-precision sensing, drug delivery, and photonic technology. Their performance depends on the regularity and monodispersity. Batch-to-batch consistency is also essential for translation and scale-up. However, precise control over these attributes remains a critical bottleneck because droplet generation and particle solidification are governed by coupled interfacial phenomena and kinetics. Unlike previous reviews that mainly concentrate on synthesis methods, this review highlights the interfacial engineering strategies that affect the formation, evolution, and solidification of droplets. It offers a comparative analysis of both conventional and innovative fabrication techniques regarding their controllability and reproducibility, including chemical synthesis, liquid-solidification, emulsification, and continuous microfluidic fabrication. Additionally, it discusses the sieving and assembly methods that refine particle populations and enable the formation of ordered structures. Finally, this study explores the applications of precision microspheres in flexible electronics, energy storage, micromotors, and clinical applications while discussing future technological challenges and development directions in this field.