Polylactide Microparticles with Tunable Morphology for Biomedical Applications

The ability to precisely control the morphology of polylactide (PLA) microparticles is crucial for their biomedical applications, yet it is a challenge due to the interdependent nature of key parameters such as size, porosity, and surface topology. This study presents a systematic approach to fabricating PLA microparticles with tunable architecture via emulsion-solvent evaporation by investigating the interplay of polymer molecular weight (44–442 kDa), solution concentration (0.5–20% w/v), and porogen type (PEG, alkanes, lithium salts). We achieved precise size control from 5 to 500 μm, dictated by solution viscosity and the polymer’s crystallization tendency, with poly(L-lactide) yielding irregular particles and poly(D,L-lactide) forming perfect spheres. Furthermore, porogen selection was critical for porosity: alkanes enabled tailored pore networks, with longer chains (e.g., decane) producing larger pores via enhanced phase separation, whereas the double-emulsion method with Li2CO3 proved superior for macroporosity due to its slow leaching kinetics. This work provides a foundational guideline for the rational design of PLA microparticles with customized properties for targeted applications in drug delivery and tissue engineering.