Fabrication of Porous Centrifugal Tube Cores Using High Internal Phase Emulsion for Size‐Selective Separation

Despite existing membrane, centrifugation, and microfluidic methods, a simple, disposable, centrifuge‐integrated device with tunable, sharp submicron‐to‐micron (0.2–5 μm) cutoff is still needed for bacterial purification, organelle isolation, and microvesicle enrichment. Here, a tunable porous centrifugal filtration device is designed to address these challenges. Using high internal phase emulsion (HIPE) templating, monolithic poly(styrene‐ co ‐butyl acrylate) porous centrifugal tube cores are fabricated with precisely controlled open‐cell architectures, featuring voids of 5–7.7 μm and windows of 1.3–2.9 μm. The dimensions of both voids and windows are systematically modulated by varying the internal phase volume fraction (75–90 vol%), surfactant concentration (8–23 wt%), and shear rate (9–18 krpm). Comprehensive characterization (SEM, DLS, contact angle) confirms structural fidelity, hydrophobicity, and reproducible filtration performance under the tested centrifugation conditions. Mechanical testing reveals that higher shear rates enhance the modulus (up to 37.76 MPa) by improving void uniformity. Filtration assays with monodisperse microspheres (0.367–2.85 μm) confirm sharp size selectivity, showing complete exclusion of 2.85 μm particles and > 86% transmission of 367 nm species. Binary separation studies validate high‐resolution, purely physical sieving. This scalable platform bridges a long‐standing functional void in lab‐scale separation, with promising applications in bacterial purification, organelle isolation, and microvesicle enrichment.