Submicron emulsions could be produced via the tip-streaming process in a flow-focusing microfluidic device. In this article, the stability of the liquid cone and thread for tip-streaming mode could be significantly improved by employing a three-dimensional flow-focusing device, in which the hydraulic resistance was adjusted by modulating the channel heights in the flow focusing area, orifice, downstream and dispersed phase inlet channel. The pressure range for tip-streaming mode was enlarged significantly compared with two-dimensional flow-focusing devices. Therefore, monodisperse emulsions were produced under this tip-streaming mode for as long as 48 hours. Furthermore, we could control the size of emulsion drops by changing the pressure ratio in three-dimensional flow-focusing devices while the liquid cone was easily retracted during the adjustment of pressure ratio in two-dimensional flow-focusing devices. Furthermore, using the uniform submicron emulsion droplets as confining templates, polyethylene glycol (PEG) particles were produced with a narrow size distribution at the sub-micrometre scale. In addition, magnetic nanoparticles were added to the emulsion for magnetic PEG particles, which can respond to magnetic field and would be biocompatible.

The dynamic breakup of emulsion droplets was demonstrated in double-layered microfluidic devices equipped with designed pneumatic actuators. Uniform emulsion droplets, produced by shearing at a T-junction, were broken into smaller droplets when they passed downstream through constrictions formed by a pneumatically actuated valve in the upper control layer. The valve-assisted droplet breakup was significantly affected by the shape and layout of the control valves on the emulsion flow channel. Interestingly, by actuating the pneumatic valve immediately above the T-junction, the sizes of the emulsion droplets were controlled precisely in a programmatic manner that produced arrays of uniform emulsion droplets in various sizes and dynamic patterns.

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