:Field’s Metal (FM) microparticles possess unique properties such as a low melting point, high moldability, and non-toxicity, making them highly applicable in various industries, including fiber-reinforced polymers, soft robotics, and mold manufacturing. However, size reduction of FM microparticles remains challenging, primarily due to the high viscosity of thixotropic mediums, which limits process efficiency and scalability. In this study, we present a high-shear thixotropic emulsion process approach to optimize the mass production of FM microparticles. We analyze the relationship between shear velocity and particle size, the influence of medium viscosity on particle formation, and the practical yield of FM microparticles. The results show that increasing shear velocity significantly reduces particle size, however beyond a certain shear threshold, the rate of size reduction diminishes due to shear stress saturation and the Hall-Petch effect. Additionally, the medium viscosity is optimized within the 6–8 wt.% range, and we demonstrate that adjusting the input mass enables high-yield and efficient large-scale production. These findings establish a scalable and cost-effective strategy for FM microparticle fabrication, balancing high yield with uniform particle morphology.

Keywords: Field’s Metal microparticle, High-shear mixing, Mass production, Size reduction