The research focuses on optimizing the production of hydrogel microspheres using droplet microfluidics for pharmaceutical and bioengineering applications. A semiempirical method has been developed to predict the dynamic interfacial tension at the interface of . These microspheres are produced in a small-scale coaxial device that is manufactured using affordable DLP/LCD 3D printing technology with a transparent photopolymer. The method was tested to design the minireactor in the device, which allows for the production of fully cross-linked microspheres that are ready for use at the output of the reactor without additional cross-linking steps in the microsphere collector. The mathematical expression for estimating the interfacial tension at the moment of formation of a hydrogel microsphere includes the Reynolds number for a two-phase liquid, the Ohnesorge number, and the surface tension at the interface for continuous medium flow (modified oil). The reliability of the prediction is confirmed for continuous medium and dispersed phase flow rates of 0.8-3.2 and 0.01-0.08 mL/min, respectively. The evolution of the interfacial tension from the moment the microspheres formed and the estimated ultimate interfacial tension in a system contributed to the reliable determination of the linear size of a minireactor. The ultimate interfacial tension of 76.5 ± 0.3 mN/m was determined using the Young-Laplace equation, which is based on measuring the surface free energy of the hydrogel as soft matter using the Owens-Wendt method. Additionally, the equilibrium static contact angle of the fully cross-linked hydrogel surface wetted with oil is measured using the sessile drop method. From a practical perspective, a method for optimizing and streamlining the high-tech manufacturing of cross-linked polymer microspheres and mini- and microchannel devices for use in bioengineering and pharmaceutical applications is suggested.
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