Upscaled Production of Satellite-Free Droplets: Step Emulsification with Deterministic Lateral Displacement

Step emulsification is a key technique for achieving scalable production of monodisperse emulsion droplets owing to its resilience to flow fluctuations. However, the persistent issue of satellite droplets, an inherent byproduct of main droplets, poses challenges for achieving truly uniform product sizes. In a previous study, we introduced a module with step-emulsifier nozzles upstream and deterministic lateral displacement (DLD) micropillar arrays downstream to generate satellite-free droplets at a low throughput. In this study, we demonstrate an upscaled parallelized setup with ten modules that were designed to produce satellite-free droplets. Each module integrated 100 step-emulsification nozzles in the upstream region with DLD micropillar arrays downstream. We conducted 3D flow simulations to ensure homogeneous distribution of the input fluids. Uniformly supplying an aqueous polyvinyl alcohol solution and an acrylate monomer as continuous and dispersed phases into the ten modules, the nozzles in each module exhibited a production rate of 539.5 ± 28.6 drop/s (n = 10). We successfully isolated the main droplets with a mean diameter of 66 μm and a coefficient of variation of 3.1% from satellite droplets with a mean diameter of 3 μm. The total throughput was 3.0 mL/h. The high yield and contamination-free features of our approach are promising for diverse industrial applications.