Droplet-based microfluidics for emulsion and solvent evaporation synthesis of monodisperse mesoporous silica microspheres

A novel method for the fabrication of monodisperse mesoporous silica particles is suggested. It is based on the formation of well-defined equally sized emulsion droplets using a microfluidic approach. The droplets contain the silica precursor/surfactant solution and are suspended in hexadecane as the continuous oil phase. The solvent is then expelled from the droplets, leading to concentration and micellization of the surfactant. At the same time, the silica solidifies around the surfactant structures, forming equally sized mesoporous particles. The procedure can be tuned to produce well-separated particles or alternatively particles that are linked together. The latter allows us to create 2D or 3D structures with hierarchical porosity.