Microcapsules are attractive core-shell configurations for studies of controlled release, biomolecular sensing, artificial microbial environments, and spherical film buckling. However, the production of microcapsules with ultra-thin shells remains a challenge. Here we develop a simple and practical osmolarity-controlled swelling method for the mass production of monodisperse microcapsules with ultra-thin shells via water-in-oil-in-water (W/O/W) double-emulsion drops templating. The size and shell thickness of the double-emulsion drops are precisely tuned by changing the osmotic pressure between the inner cores and the suspending medium, indicating the practicability and effectiveness of this swelling method in tuning the shell thickness of double-emulsion drops and the resultant microcapsules. This method enables the production of microcapsules even with an ultra-thin shell less than hundreds of nanometers, which overcomes the difficulty in producing ultra-thin-shell microcapsules using the classic microfluidic emulsion technologies. In addition, the ultra-thin-shell microcapsules can maintain their intact spherical shape for up to 1 year without rupturing in our long-term observation. We believe that the osmolarity-controlled swelling method will be useful in generating ultra-thin-shell polydimethylsiloxane (PDMS) microcapsules for long-term encapsulation, and for thin film folding, buckling and rupturing investigation.
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