Fabrication of weaved ceramic mesh from green microfibers based on cross-flow microfluidics

Abstract Microfibers-weaved ceramic filters are in increasing demand due to their high filtration efficiency, stable structure and remarkable ceramic properties in water and gas treatment. To date, it remains a challenge to find an effective way to weave ceramic microfibers. This work demonstrates a novel strategy that combines gel-casting and in situ cross-flow microfluidic molding to fabricate highly flexible and shape-retentive green microfibers and then weaves them before sintering. By tailoring the curing temperature and flow rate, the diameter and surface morphology of the microfiber is accordingly tuned. Besides mesh structure, the microfibers can also be weaved into more complex three-dimensional structures such as dragonfly knot, Chinese knot, etc. Benefitting from the widely used solution system and microfluidic method, this system can serve as a general and stable platform for preparing microfibers-weaved ceramic filters made from different materials, thus holds great potential in a wide range of working conditions.