Surface wrinkled particles are ubiquitous in nature and present in different sizes and shapes, such as plant pollens and peppercorn seeds. These natural wrinkles provide the particles with advanced functions to survive and thrive in nature. In this work, by combining flow lithography and plasma treatment, we have developed a simple method that can rapidly create wrinkled non-spherical particles, mimicking the surface textures in nature. Due to the oxygen inhibition in flow lithography, the non-spherical particles synthesized in a microfluidic channel are covered by a partially cured polymer (PCP) layer. When exposed to plasma treatment, this PCP layer rapidly buckles, forming surface-wrinkled particles. We designed and fabricated various particles with desired shapes and sizes. The surfaces of these shapes were tuned to created wrinkle morphologies by controlling UV exposure time and the washing process. We further demonstrated that wrinkles on the particles significantly promoted cell attachment without any chemical modification, potentially providing a new route for cell attachment for various biomedical applications.

A microfluidic flow lithography approach was investigated to synthesize highly porous nonspherical particles and Janus particles in a one-step and high-throughput fashion. In this study, using common solvents as porogens, we were able to synthesize highly porous particles with different shapes using ultraviolet (UV) polymerization-induced phase separation in a microfluidic channel. We also studied the pore-forming process using operating parameters such as porogen type, porogen concentration, and UV intensity to tune the pore size and increase the pore size to submicron levels. By simply coflowing multiple streams in the microfluidic channel, we were able to create porous Janus particles; we showed that their anisotropic swelling/deswelling exhibit a unique optical shifting. The distinctive optical properties and the enlarged surface area of the highly porous particles can improve their performance in various applications such as optical sensors and drug loading.

Environment-responsive hydrogel structures are of great interest in materials research and have a wide range of applications. By using a flow lithography technique, we report a one-step and high-throughput fabrication method for the synthesis of highly pH-responsive hydrogels with designed shape transformations. In this method, heterogeneous hydrogels with porous and nonporous layers are synthesized using a single UV exposure in a microfluidic channel. During the UV polymerization, the porous layers, which are formed by using polymerization-induced phase separation (PIPS), significantly increase the swelling capability and enhance the swelling rate of the hydrogels. Because the flow-lithography approach allows various patterns of porous/nonporous layers with great control and enables the simple integration of PIPS, resultant layered hydrogels show extraordinary deformations with desired pH response. More importantly, our fabrication approach can not only make 2D deformation of hydrogel structures such as bending but also can achieve 3D structural deformation such as helical and buckling structures, enabled by nonuniform UV polymerization we developed.