Controlled electrosprayed formation of non-spherical microparticles

Fabrication of biocompatible microparticles, such as alginate particles, with the possibility of controlling the particles' morphology in a high-throughput manner, is essential for pharmaceutical and cosmetic industries. Even though the shape of alginate particles has been shown to be an important parameter in controlling drug delivery, there are very limited manufacturing methods to produce non-spherical alginate microparticles in a high-throughput fashion. Here, we present a system that generates non-spherical biocompatible alginate microparticles with a tunable size and shape, and at high-throughput, using an electrospray technique. Alginate solution, which is a highly biocompatible material, is flown through a needle using a constant flow rate syringe pump. The alginate phase is connected to a high-voltage power supply to charge it positively. There is a metallic ring underneath the needle that is charged negatively. The applied voltage creates an electric field that forces the dispensing droplets to pass through the metallic ring toward the collection bath. During this migration, droplets break up to smaller droplets to dissipate their energy. When the droplets reach the calcium chloride bath, polymerization happens and solidifies the droplets. We study the effects of changing the distance from the needle to the bath, and the concentration of calcium chloride in the bath, to control the size and the shape of the resulting microparticles.