Abstract: Provided are scalable, parallelized microfluidic chips that include arrays of microfluidic mixing channels for large-scale production of lipid nanoparticles, among other products. The disclosed chips can operate with a single set of inlets and outlet, and achieve production rates in excess of those achieved by existing methods. The disclosed devices provide large-scale production of formulations while still maintaining the physical properties and potency typical of existing methods of producing such formulations. Also provided are related methods of using the disclosed devices.

Abstract: Microfluidic devices having a construct formed from perfluoropolyether and poly(ethylene glycol) diacrylate. The construct includes an inlet for receiving a continuous phase fluid, an inlet for receiving a dispersed phase fluid, and a plurality of channels extending through the construct. The plurality of channels are in fluid communication with both the inlet of the continuous phase fluid and the inlet of the dispersed phase fluid. The construct further includes a plurality of microdroplet generators configured to produce microdroplets, each of the microdroplet generators in fluid communication with the plurality of channels. Additionally, the construct includes an outlet formed in the construct and in fluid connection with the plurality of microdroplet generators.

Abstract: In one embodiment, a microfluidic device has a substrate that defines a first inlet for a continuous phase fluid, a second inlet for a dispersed phase fluid, and droplet generators that can produce micro-droplets from the continuous and dispersed phase fluids. The substrate defines (i) a plurality of delivery channels in fluid communication with the first and second inlets, each delivery channel having a first dimension along a first plane that is perpendicular to a transverse direction, and (ii) a plurality of trenches that extend from the delivery channels towards the droplet generators along the transverse direction. Each trench has a second dimension along a plane that is perpendicular to the transverse direction that is smaller than the first dimension. The substrate defines a plurality of vias that extend from the trenches to the droplet generators so as to fluidly connect the delivery channels with the droplet generators.

Abstract: Microfluidic devices having a construct formed from perfluoropolyether and poly(ethylene glycol) diacrylate. The construct includes an inlet for receiving a continuous phase fluid, an inlet for receiving a dispersed phase fluid, and a plurality of channels extending through the construct. The plurality of channels are in fluid communication with both the inlet of the continuous phase fluid and the inlet of the dispersed phase fluid. The construct further includes a plurality of microdroplet generators configured to produce microdroplets, each of the microdroplet generators in fluid communication with the plurality of channels. Additionally, the construct includes an outlet formed in the construct and in fluid connection with the plurality of microdroplet generators.

Abstract: Aspects of the present invention relate to apparatuses for microdroplet generation and methods of manufacturing such apparatuses. In accordance with one aspect, a method for manufacturing a microdroplet generator having a plurality of flow-focusing generators includes forming a cavity between a first plate and a second plate, the second plate being a soft master. The cavity defining the plurality of flow focusing generators, a first plurality of channels, and a second plurality of channels. The method further includes supplying a resin to the cavity, applying pressure to one or both of the first plate or the second plate; and curing the resin.