Generation of porous solids with well-controlled morphologies by combining foaming and flow chemistry on a Lab-on-a-Chip

We review here how millifluidic techniques can be used to construct versatile Labs-on-a-Chip, in which on-chip bubble generation and flow chemistry are efficiently combined to generate porous solids with highly monodisperse and ordered pore structures. With this approach, a liquid foam with well-controlled structural and chemical properties is first generated, which is then solidified in situ. We discuss here the interplay of various important processing parameters. In particular, we demonstrate that solidification time and foam life time need to be matched wisely in order to control precisely the properties of the final porous material. We also discuss a simple and inexpensive route to the manufacture of chemically and pressure-resistant, millifluidic Labs-on-a-Chip via the machining and hot-pressing of Cyclic Olefin Copolymers. We illustrate our review using the example of the generation of two types of hydrogel foams (synthetic acrylamide-based and biopolymer chitosan-based) and of particle foams, which may be used as green bodies for the manufacture of porous ceramics. The newly designed materials can be used to investigate fundamental questions of the structure–property relationship of porous solid.