Hydrodynamically directed multiscale assembly of shaped polymer fibers

A long-sought goal of material science is the development of fabrication processes by which synthetic materials can be made to mimic the multiscale organization many natural materials utilize to achieve unique functional and material properties. Here we demonstrate how the microfluidic fabrication of polymer fibers can take advantage of hydrodynamic forces to simultaneously direct assembly at the molecular and micron scales. The microfluidic device generates long fibers by initiating polymerization of a continuously flowing fluid via UV irradiation within the microfluidic channel. Prior to polymerization, hydrodynamic shear forces direct molecular scale assembly and a combination of hydrodynamic focusing and advection driven by grooves in the channel walls manipulate the cross-sectional shape of the pre-polymer stream. Polymerization subsequently locks in both molecular scale alignment and micron-scale fiber shape. This simple method for generating structures with multiscale organization could be useful for fabricating materials with multifunctionality or enhanced mechanical properties.