Large Ultrathin Shelled Drops Produced via Non‐Confined Microfluidics

We present a facile approach for producing large and monodisperse core–shell drops with ultrathin shells using a single‐step process. A biphasic compound jet is introduced into a quiescent third (outer) phase that ruptures to form core–shell drops. Ultrathin shelled drops could only be produced within a certain range of surfactant concentrations and flow rates, highlighting the effect of interfacial tension in engulfing the core in a thin shell. An increase in surfactant concentrations initially resulted in drops with thinner shells. However, the drops with thinnest shells were obtained at an optimum surfactant concentration, and a further increase in the surfactant concentrations increased the shell thickness. Highly monodisperse (coefficient of variation smaller than 3 %) core–shell drops with diameter of ～200 μm–2 mm with shell thickness as small as ～2 μm were produced. The resulting drops were stable enough to undergo polymerisation and produce ultrathin shelled capsules.