Preparation of particle-loaded foams, followed by drying, sintering and/or cross-linking are widely explored routes for developing lightweight ceramics with high mechanical strength. The non-sintered dry ceramic foams are less studied due to their intricate production and the assumed poor mechanical strength of the obtained “green” materials. Here we produce lightweight ceramics from foamed particle suspensions containing spherical silica particles with radii varied between 4.5 nm and 7 µm. The wet foams are prepared in the presence of cationic surfactant and were dried at ambient conditions to obtain porous materials with mass densities between 100 and 700 kg/m3. The materials containing smaller particles exhibited much higher strength (by up to 2000 times), approaching that of the sintered materials. A new theoretical expression for predicting the mechanical strength of such materials is derived and is used to explain the measured strengths of the produced materials through the van der Waals attraction between the particles in the final dry materials.

Lipid nanoemulsions and nanosuspensions are used as flavor carriers and bubble stabilizers in soft drinks and foods, as well as delivery vehicles for lipophilic drugs in pharmaceutics. Common techniques for their formation are the high-pressure and ultrasonic homogenizers. These techniques dissipate most of the input energy, which results in excessive heating and generation of free radicals that might modify sensitive ingredients. Low energy methods are also used in some applications, but they have specific limitations restricting their universal use. In the current study, we propose an alternative approach – a flow reactor with a variable temperature, which utilizes the lipids’ polymorphic transitions to induce spontaneous fragmentation of the lipid microparticles into nanoparticles. The reactor allows us to obtain emulsions or suspensions with particle diameters tunable between 20 and 800 nm when appropriate surfactants, temperature profiles, and flow rates are applied. The fragmentation is comparable to that in a high-pressure homogenizer at ca. 500 bars or higher, without creating emulsion overheating or cavitation typical for the conventional methods. The flow reactor can be scaled up to industrial applications using simple scaling rules.

High-pressure homogenizers, typically used for producing nanoemulsions at the industrial scale, are energy and maintenance intensive, and limited to produce only dilute, low viscosity nanoemulsions. We propose an alternative approach to produce dilute to concentrated food-grade nanoemulsions with droplet size ranging between 100 and 500 nm using rotor-stator homogenization. Gum Arabic (GA) or modified starch (MS) was used as both viscosity modifier and emulsion stabilizer. GA and MS have relatively low surface activity compared to the common low-molecular-mass surfactants used typically for nanoemulsion preparation. The main differences between GA and MS are the lower viscosity of the GA solutions, compared to MS solutions, and the faster adsorption of MS, as compared to GA. The obtained results show that stable nanoemulsions are formed by rotor-stator homogenization when the rapidly adsorbing MS is used as emulsifier. Much larger drops are formed during emulsification with GA, which is due to significant drop-drop coalescence in the respective emulsions. The experimental results for the nanoemulsions prepared with MS are well-described by the theoretical expression for emulsification in turbulent viscous regime, after proper account for the effects of temperature and drop-drop interactions in the sheared emulsions.

Particle surface roughness and chemistry play a pivotal role in the design of new particle-based materials. Although the adsorption of rough particles has been studied in the literature, desorption of such particles remains poorly understood. In this work, we specifically focus on the detachment of rough and chemically modified raspberry-like microparticles from water/oil interfaces using colloidal-probe atomic force microscopy. We observe different contact-line dynamics occurring upon particle detachment (pinning vs sliding), depending on both the particle roughness and surface modification. In general, surface roughness leads to a reduction of the desorption force of hydrophobic particles into the oil and provides a multitude of pinning points that can be accessed by applying different loads. Our results hence suggest future strategies for stabilization and destabilization of Pickering emulsions and foams.

Shape-anisotropic polymeric micro- and nanoparticles are of significant interest for the development of novel composite materials, lock-and-key assemblies, and drug carriers. Currently, syntheses require external confinement in microfluidic devices or lithographic techniques associated with significant infrastructure and low productivity, so new methods are necessary to scale-up such production efficiently. Here we report bottom-up polymerization of regular shape-anisotropic particles (polygonal platelets with different numbers of edges, with and without protruding asperities, and fibrilar particles with controllable aspect ratios), with size control over 4 orders of magnitude (∼50 nm-1 mm). Polymerization also enables the study of much smaller shapes than could previously be studied in water suspensions, and we study the fundamental limits of the self-shaping transition process driving these transformations for monomer oil droplets of stearyl methacrylate (SMA) monomer oil. We show the method is compatible with a variety of polymerizing monomers and functional modifications of the particles (e.g., composites with magnetic nanoparticles, oil-soluble additives, etc.). We also describe postsynthetic surface modifications that lead to hierarchical superstructures. The synthesis procedure has great potential in efficient nanomanufacturing as it can achieve scalable production of the above shapes in a wide range of sizes, with minimum infrastructure and process requirements and little maintenance of the equipment.