AUTOMATED LIQUID ENCAPSULATION MACHINE

This project focused on developing an innovative system for encapsulating precise volumes of liquid within thin UV-cured resin shells, forming perfect spheres that could be intentionally ruptured when required. I led the physical experimentation to understand and control liquid surface tension dynamics while designing sub-microliter dosing mechanisms. I also engineered and constructed the complete system, addressing complex challenges including precision fluid flow control and prevention of micro air bubble formation. The result was a fully automated machine capable of consistently producing flawless encapsulated spheres, advancing the state of the art in liquid encapsulation technology.

System Capabilities

The machine performs a controlled encapsulation process that combines precise fluid handling with UV curing technology. It produces consistent, high-quality capsules through an automated process that maintains strict quality control parameters.

Key Production Features:

• Production of uniform spherical capsules with customizable shell thickness

• Precise control of internal fluid volume (sub-microliter dosing)

• UV-cured resin shell for stability and controlled rupture

• Automated batch processing for high throughput production

System Architecture

The system integrates several precision components working in harmony:

1. Dual Precision Stepper Motors

   • 200 steps per revolution with 1.8° precision

   • Non-captive configuration with lead screw (1.5μm per step)

   • Controls syringes for hydrophilic fluid (Blue) and resin (Gray)

2. Peristaltic Pump System

   • 24V stepper motor with 6 rollers

   • Transfers completed capsules to curing fluid and collection vessel

   • Programmable multi-velocity control with directional capability

3. UV Curing System

   • UV5TZ-405-30 LEDs (405nm wavelength)

   • Parallel array configuration for uniform curing

   • 30° viewing angle for optimal coverage

   • Programmable activation timing for precise shell formation

4. Control System

   • External GUI interface via PC/laptop

   • Programmable cycle parameters for customized production

   • Real-time monitoring and control of all machine components

Benefits and Applications

1. Precision and Consistency

   • Uniform capsule production with minimal variation

   • Sub-microliter control of internal contents

   • Consistent shell thickness for predictable rupture properties

2. Flexibility

   • Programmable parameters for different capsule specifications

   • Compatible with various hydrophilic fluids

   • Adjustable production rates

3. Automation

   • Reduces manual intervention and human error

   • Batch processing capability for high-volume production

   • Automated quality control through parameter consistency

4. Applications

   • Pharmaceutical: controlled-release drug delivery systems

   • Cosmetics: encapsulated active ingredients

   • Research: precise reagent delivery

   • Food industry: flavor or nutrient encapsulation

   • Specialty chemicals: reactive component isolation