Solvent-Resistant Perfluoropolyether Microfluidic Devices with Microfibrous Channels for the Production of Poly(ε-caprolactone) Microspheres Containing Dexamethasone

A microfluidic device with microfibrous channels was prepared using perfluoropolyether (PFPE) and poly(ethylene glycol) diacrylate (PEG-DA). PFPE was chosen as a major material for the device due to its excellent solvent resistance. PEG-DA was used in the device to improve its hydrophilicity. Microfibrous channels with different diameters (approximately 12 and 17 μm) were developed using an electrospun disc as a template. Compared to a polydimethylsiloxane microfluidic device, the PFPE microfluidic device exhibited a significantly lower swelling ratio. The continuous production of poly(ε-caprolactone) (PCL) microspheres with dexamethasone was achieved using the oil-in-water (O/W) emulsification and solvent evaporation methods. The microsphere size was decreased with the use of smaller microfibrous channels at a higher flow rate of the continuous phase. PCL microspheres prepared by the PFPE microfluidic device showed higher encapsulation efficiency than conventional homogenization. The addition of poly(ethylene glycol) (PEG, 5 wt %) in the discontinuous phase enhanced the encapsulation efficiency to 39.4%. PCL microspheres with PEG showed more sustained release profiles than PCL microspheres without PEG. These results indicate that the PFPE microfluidic device with microfibrous channels can be used as a platform for the continuous production of drug carriers.