A polydimethylsiloxane (PDMS) microfluidic chip with well-interconnected microfibrous channels was fabricated by using an electrospun poly­(ε-caprolactone) (PCL) microfibrous matrix and 3D-printed pattern as templates. The microfiber-templated microfluidic chip (MTMC) was used to produce nanoscale emulsions and spheres through multiple emulsification at many small micro-orifice junctions among microfibrous channels. The emulsion formation mechanisms in the MTMC were the cross-junction dripping or Y-junction splitting at the micro-orifice junctions. We demonstrated the high throughput and continuous production of water-in-oil emulsions and polyethylene glycol-diacrylate (PEG-DA) spheres with controlled size ranges from 2.84 μm to 83.6 nm and 1.03 μm to 45.7 nm, respectively. The average size of the water droplets was tuned by changing the micro-orifice diameter of the MTMC and the flow rate of the continuous phase. The MTMC theoretically produced 58 trillion PEG-DA nanospheres per hour without high shear force. In addition, we demonstrated the higher encapsulation efficiency of the PEG-DA microspheres in the MTMC than that of the microspheres fabricated by ultrasonication. The MTMC can be used as a powerful platform for the large-scale and continuous productions of emulsions and spheres.

Poly( -caprolactone) (PCL)-based polyurethane (PU) foam scaffolds with different mechanical properties are fabricated using a gas foaming technique to use as porous substitutes for ear or bone with cartilage. PCL diol or triol is used as a polyol in PU foam for biocompatibility and biodegradation, with an aqueous gelatin solution as a blowing agent. The highly porous inner and outer structures of the scaffolds are developed by employing a silicone surfactant and sulfuric acid, respectively. The PU scaffolds prepared by PCL diol show ductile and flexible properties, whereas the PU scaffolds prepared by PCL triol exhibit high compression strength. In vitro test reveals the low toxicity of the PU scaffolds and the high ALP activity of MC3T3-E1 cells in the PU scaffold prepared by PCL triol. By taking advantage of the difference in mechanical properties, customized PU scaffolds with ear or bone shapes are fabricated using a silicone mold. The PU scaffolds with two compartments of PCL diol and triol (corresponding to cartilage and bone, respectively) are fabricated as a substitute for bone with cartilage. It is believed that the PU scaffolds with highly porous structure and controlled mechanical properties have wide potential application for tissue engineering.

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