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:
- 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)
- 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
- 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
- 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
- Precision and Consistency
- Uniform capsule production with minimal variation
- Sub-microliter control of internal contents
- Consistent shell thickness for predictable rupture properties
- Flexibility
- Programmable parameters for different capsule specifications
- Compatible with various hydrophilic fluids
- Adjustable production rates
- Automation
- Reduces manual intervention and human error
- Batch processing capability for high-volume production
- Automated quality control through parameter consistency
- 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
