Custom Microfluidic API Encapsulation Solutions

At Creative Biolabs, we leverage state-of-the-art microfluidic platforms to deliver Custom API Encapsulation Solutions tailored to your specific formulation and research objectives. Our integrated services cover the full life cycle from conceptual design to scalable production.

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The encapsulation of active pharmaceutical ingredients (APIs) is a cornerstone technology in modern drug formulation, enabling controlled release, improved stability, and targeted delivery of small molecules, biologics, and advanced therapeutic agents.

Traditional batch encapsulation methods often suffer from wide particle size distributions, limited reproducibility, and high reagent consumption. In contrast, microfluidic systems offer exceptional control over fluid dynamics and reaction environments at the microscale, enabling highly monodisperse particles with tailored physical and functional properties.

If you're exploring microfluidic routes to enhance API encapsulation outcomes—whether for early R&D or product development—Creative Biolabs is ready to help.

Our Service Portfolio

Creative Biolabs' Custom Microfluidic API Encapsulation Solutions encompass the entire project spectrum—from strategic consultation to deliverables, analytical validation, and scale-up support. Below is an overview of our core offerings:

Technical Consultation & Feasibility Assessment

Our first step is a deep technical consultation where our experts collaborate with your team to understand:

API physicochemical properties
Target particle size and distribution
Desired release kinetics
Biocompatibility and regulatory considerations
Formulation goals and envisioned applications

This early dialogue enables an informed feasibility assessment and project roadmap tailored to your scientific and practical needs.

Custom Chip Design & Engineering

We design bespoke microfluidic chips optimized for your API encapsulation goals. This includes:

Selection of microchannel geometry and architecture
Integration of droplet generators, mixers, and phase junctions
Material selection based on chemical compatibility (e.g., solvent resistance, surface treatment)
Interfaces for pumps, sensors, and collection systems

Our engineers combine fluid dynamics modeling with practical fabrication constraints to craft chips that deliver reliable and reproducible performance.

Process Development & Optimization

In our development workflows:

Flow parameters (rates, ratios)
Phase compositions
Temperature and pressure conditions

These are systematically varied to optimize encapsulation outcomes (size distribution, API loading, stability). We iterate quickly using small sample volumes to refine parameters before moving to larger runs.

Fabrication & Manufacturing

Once your microfluidic system design and process parameters are validated, we pivot to fabrication and scaling. Creative Biolabs deploys advanced manufacturing techniques—including photolithography, soft lithography, and precision molding—to produce high-quality chips with rigorous quality control.

For clients needing higher throughput, we offer options to parallelize chip arrays or support continuous flow production, maintaining monodispersity and product consistency across scales.

Analytical Validation & Characterization

We provide a suite of analytical assessments to characterize encapsulation products:

Particle size and morphology (via DLS, microscopy)
Encapsulation efficiency
Release profiles
Stability studies

These data packages support process validation, refinement, and regulatory submission needs.

Our service extends to full integration support, helping clients align microfluidic encapsulation systems with existing workflows or downstream processes.

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Microfluidic Technologies & Engineering Platforms

At Creative Biolabs, our custom API encapsulation solutions are supported by a diverse portfolio of advanced microfluidic engineering platforms. Different encapsulation strategies require different flow architectures and chip configurations. We carefully select and customize microfluidic designs based on API properties, formulation objectives, and scalability requirements.

Technologies & Platforms	Descriptions
Flow-Focusing Microfluidics	Flow-focusing geometries are widely used for generating highly uniform droplets and nanoparticles. In this configuration, a dispersed phase containing the API is squeezed by continuous phase streams, forming droplets at controlled frequencies.
T-Junction Microfluidic Systems	T-junction microfluidics provide a robust and simple approach for droplet generation. The shear force exerted by the continuous phase controls droplet formation.
Coaxial & Multi-Layer Flow Systems	For advanced drug delivery applications, we design coaxial flow microfluidic systems capable of generating multi-layered or core-shell particles.
Parallelized Microfluidic Arrays for Scale-Up	To address industrial translation challenges, we design chips with parallel channel networks that multiply throughput without sacrificing monodispersity.

Materials for API Encapsulation

The choice of encapsulation material is critical for drug stability, release kinetics, and biocompatibility. Creative Biolabs provides expertise in a wide range of carrier materials.

Polymeric Carriers
- PLGA
- PEGylated polymers
- Biodegradable copolymers
- pH-responsive polymers
These systems allow tunable degradation rates and sustained release profiles.
Lipid-Based Systems
- Liposomes
- Solid lipid nanoparticles
- Nanostructured lipid carriers
Lipid-based encapsulation is especially suitable for hydrophobic APIs and nucleic acid therapeutics.
Hydrogel Microcapsules
Hydrogel systems provide:
- Mild encapsulation conditions
- High water content compatibility
- Excellent for biologics and peptides
Hybrid Organic–Inorganic Carriers
For specialized applications, we support silica-based or hybrid systems offering enhanced mechanical strength and stability.

Encapsulation of Diverse API Classes

Our microfluidic systems are compatible with a broad spectrum of active ingredients.

Small Molecules

Poorly soluble compounds
Cytotoxic drugs
High-potency APIs

Peptides & Proteins

Sensitive biologics
Enzyme therapeutics
Antibody fragments

Nucleic Acids

mRNA
siRNA
DNA constructs

Combination Therapies

Co-encapsulation strategies
Sequential drug release systems

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Client Testimonials

"We approached Creative Biolabs to reformulate a highly hydrophobic oncology API that had failed traditional nanoprecipitation methods. Their microfluidic platform enabled precise particle size control with exceptional reproducibility. Their team was technically rigorous and responsive throughout the development process."

— Pharmaceutical R&D Director, Oncology Program

"We required a scalable microfluidic encapsulation system for lipid nanoparticle formulation. Creative Biolabs designed a custom parallelized chip architecture that allowed us to transition from lab-scale screening to pilot-scale production without changing formulation parameters. The technology transfer support was outstanding."

— Senior Scientist, mRNA Therapeutics Startup

"The team provided a customized core-shell microcapsule design for dual-drug release studies. Their engineering team worked closely with us to optimize flow ratios and polymer selection. The resulting particles demonstrated predictable pulsatile release behavior. The analytical documentation was comprehensive and publication-ready."

— University Principal Investigator, Controlled Release Research

"What impressed us most was the detailed feasibility assessment at the start of the project. They evaluated our API's physicochemical constraints before committing to a design strategy. The transparency and technical depth significantly reduced our development risk."

— Biotech Formulation Lead, Rare Disease Therapy

Published Data

PLGA-based nanoparticles with a wide size range using a microfluidic platform

Employing PLGA NPs to establish a large range of size-controlled drug delivery systems and achieve size-selective drug delivery targeting remains a challenge for therapeutic development for different diseases. In this study, the researchers employed a microfluidic device to control the size of PLGA NPs. Microfluidic devices were used to achieve tunable particle sizes in the sub-200 nm range for PLGA/PEG-PLGA and their hybrid systems, and it was verified that the particle size could still be controlled after loading a hydrophobic model drug (paclitaxel).

Fabrication of microfluidic devices. (OA Literature) Fig.1 Schematics of the microfluidic device to prepare blank or PTX-loaded NPs.^1,2

References

Bao, Yi, et al. "Preparation of size-tunable sub-200 nm PLGA-based nanoparticles with a wide size range using a microfluidic platform." PLoS One 17.8 (2022): e0271050. https://doi.org/10.1371/journal.pone.0271050
Distributed under Open Access license CC BY 4.0, without modification.

Created January 2026

FAQs

How do I determine whether my API is suitable for microfluidic encapsulation?

A: Microfluidic encapsulation is highly versatile and compatible with a broad range of APIs, including hydrophobic small molecules, peptides, proteins, and nucleic acids. Suitability primarily depends on solubility profile, chemical stability, sensitivity to shear and solvents, desired release kinetics, and required particle size range. During our feasibility assessment, we analyze your API's physicochemical characteristics and recommend appropriate carrier materials and chip architectures.

Can you encapsulate multiple APIs within the same particle?

A: Yes. We offer multi-compartment and core-shell microfluidic designs that enable co-encapsulation of compatible APIs, spatial separation of incompatible drugs, sequential or staged release profiles, and combination therapy formulations. Our coaxial flow systems are particularly effective for dual-API encapsulation strategies.

What is the typical timeline for a custom microfluidic encapsulation project?

A: Timelines vary depending on complexity. For advanced multi-layer systems or regulatory-aligned projects, timelines may extend accordingly. We provide a detailed project schedule after initial consultation.

Can sensitive biologics such as proteins or mRNA be safely encapsulated?

A: Yes. We design low-shear, temperature-controlled microfluidic systems specifically for biologics. Protective encapsulation matrices reduce degradation risks, and solvent selection is carefully optimized to preserve structural integrity and biological activity. For nucleic acid therapeutics, we commonly develop lipid-based nanoparticle systems compatible with mRNA and siRNA delivery.

How much API material is required for initial development?

A: One advantage of microfluidic systems is low material consumption. Initial feasibility studies typically require significantly less API than conventional batch methods. Exact quantities depend on formulation complexity, but microfluidics is particularly beneficial when working with scarce or high-cost APIs.

How does microfluidic encapsulation compare cost-wise to traditional methods?

A: While initial chip fabrication may represent an upfront investment, microfluidic systems often reduce reagent waste, batch failure risk, development time, and cale-up unpredictability. Over the full product development lifecycle, microfluidic approaches can be more cost-efficient and risk-mitigating than conventional batch techniques.

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