Microfluidics for Nanoparticle Synthesis
📌 Batch encapsulation methods result in broad particle size distributions and low reproducibility, making them less ideal for precise drug delivery systems.
💧 Droplet microfluidics offers continuous flow processing, ensuring very narrow particle distributions (CV as low as 1% or below) and high batch-to-batch consistency.
💊 Microfluidics enables highly efficient encapsulation, sometimes exceeding 90%, while minimizing input energy, which protects fragile materials like complex proteins.
🌱 A nucleation and growth method uses miscible liquids where mixing of an anti-solvent causes polymer strands to grow into particles, offering highly controllable particle sizes, ranging from 40 nm to 800 nm.

Comparison of Batch vs. Continuous Flow Encapsulation
⏳ Batch processing typically takes 3 to 5 hours with low encapsulation efficiency, generally 5% to 20%.
🚀 Continuous flow microfluidics reduces reaction time to 2 to 10 minutes (sometimes just 30 seconds) with significantly improved encapsulation efficiency of 80% to 95%.
🔬 Microfluidics allows for creating unique structures, such as encapsulating powdered API into hydrophobic PLGA beads with nearly 100% encapsulation efficiency, or forming double emulsions (water droplets inside PLGA shells) for spike release profiles.

Characterization with Multi-Angle Dynamic Light Scattering (MALS)
📉 Standard Dynamic Light Scattering (DLS) detects light at a single angle, providing only an intensity-weighted average particle size, often biasing results towards larger particles (e.g., reading $100\text{ nm}$ when $40\text{ nm}$ and $300\text{ nm}$ particles are present).
✨ The Zetasizer Ultra's MALS feature measures at multiple angles (e.g., $0^{\circ}, 90^{\circ}$, and forward scatter) and uses a specialized algorithm to resolve distinct populations, correctly identifying samples with both $\sim 200\text{ nm}$ and $\sim 700\text{ nm}$ particles, which standard DLS cannot resolve.
⏱️ Combining microfluidics with MALS accelerates development by eliminating the need for time-consuming and destructive techniques like TEM/SEM, which previously required days of analysis and skilled operators.

Development Efficiency and Throughput
🔁 The integration of microfluidics and MALS creates a fast "build-measure-learn" cycle, allowing Particle Works to iterate quickly on R&D, achieving up to 40 samples per day.
📈 Throughput scales significantly: R\&D systems process $\sim 30\text{ grams/day}$, while multiplexed systems reach 3 to $5\text{ kg/day}$, with industrial systems targeting up to $50\text{ kg/day}$.
🤔 MALS can estimate particle concentration (particles/mL) with reasonable accuracy (often below 20% error) when used as a screening tool, though it is primarily used for size distribution analysis (which accounts for 90% of MALS usage in the lab).

Key Points & Insights
➡️ Microfluidics is superior to batch for creating highly uniform nanoparticles, offering better control over size distribution (CV $\le 1\%$) and much higher encapsulation yields.
➡️ Use MALS technology to quickly resolve multimodal particle populations in minutes, avoiding slower, expensive, and potentially sample-destroying techniques like TEM/SEM.
➡️ The fast "build-measure-learn" loop enabled by continuous flow synthesis and in-line/rapid characterization drastically lowers R\&D costs and accelerates product finalization.

📸 Video summarized with SummaryTube.com on Jan 12, 2026, 02:45 UTC