We comparatively review two versatile
approaches employed in the
precise formation of polymer particles, with length scales from 10s
of nm to to 100s μm, from ternary polymer(s), solvent and nonsolvent
mixtures. Flash nanoprecipitation (FNP) utilizes an opposing jet arrangement
to mix a dilute polymer solution and a nonsolvent in confinement,
inducing a rapid (∼millisecond) chain collapse and eventual
precipitation of nanoparticles (NPs) of 10–1000 nm diameters.
FNP of polymer mixtures and block copolymers can yield a range of
multiphase morphologies with various functionalities. While droplet
solvent extraction (DSE) also involves the exposure of a polymer solution
to a nonsolvent, in this case the polymer solution is templated into
a droplet prior to solvent extraction, often using microfluidics,
resulting in polymer particles of 1–1000 μm diameter.
Droplet shrinkage and solvent exchange are generally accompanied by
a series of processes including demixing, coarsening, phase inversion,
skin formation, and kinetic arrest, which lead to a plethora of possible
internal and external particle morphologies. In the absence of external
flow fields, DSE corresponds effectively to nonsolvent induced phase
separation (NIPS) in a spherical geometry. In this review, we discuss
the requirements to implement both approaches, detailing consequences
of ternary solution phase behavior and the interplay of the various
processes underpinning particle formation and highlighting the similarities,
differences, and complementarity of FNP and DSE. In addition to reviewing
previous work in the field, we report comparative experimental results
on the formation of polystyrene particles by both approaches, emphasizing
the importance of solution phase behavior in process design.