Microparticles and a system and method for the synthesis of microparticles

A method of producing microparticles using an emulsion based synthesis route, the method comprising:

• (i) providing a first fluid phase and a second fluid phase, wherein the first fluid phase is a continuous phase and the second fluid phase is a dispersed phase comprising a dispersed material, wherein the continuous phase is immiscible with the dispersed phase;
• (ii) providing a shear device having a first inlet for the first continuous phase and a separate second inlet for the second dispersed phase, the shear device having a rotor configured to revolve inside a stationary stator and an annular gap between the rotor and stator in which emulsification occurs;
• (iii) mixing the first continuous phase and the second dispersed phase in the presence of a surfactant in the shear device to form an emulsion of droplets of controllable size and uniformity of droplet size distribution, wherein the mixing step comprises an emulsifying step where the second dispersed phase is emulsified into the first continuous fluid phase in the shear device;
• (iv) controlling a volume fraction of the second dispersed phase during the mixing step by controlling the flow rate of the first continuous phase at the first inlet and the second dispersed phase at the second inlet;
• and
• (v) drying the emulsion to form microparticles of controllable size and uniformity of particle size distribution, and wherein the microparticles may comprise spherical, crumpled, dimpled, porous or hollow microparticles morphology.