Abstract

3D Hydrodynamic Focusing Using 3D-Printed Microfluidic Nozzles for Complex Microfluidic Fiber Fabrication

Vivek Rajasenan, PhD Candidate, UCLA

Microfibers are indispensable in various fields including bioprocessing, tissue engineering, optics, and medicine. Current methods for fabricating microfibers often rely on complex hydrodynamic and inertial shaping techniques, limiting capability and scalability. Our work presents microfiber fabrication by utilizing coaxial flow patterns enabled by low-cost, 3D printed nozzles. This approach allows for the rapid prototyping of intricate fiber structures within hours, bypassing the need for complex device fabrication protocols. Through three-dimensional hydrodynamic focusing, we achieve continuous and stable photopolymerization of monomer solutions, yielding microfibers with feature resolutions below 100 micrometers. Our method enables the production of diverse microfiber shapes, including circular, non-circular, and hollow-shell architectures, with the capability of incorporating multiple materials. Furthermore, we demonstrate the parallelization of devices to scale fiber production. These advancements have broad implications in biosensing, drug delivery, gas exchange, fiber optics, and soft robotics, enhancing capabilities across various disciplines.