Two adjacent fluids passing through a grooved microfluidic channel can be directed to form a sheath around a prepolymer core; thereby determining both shape and cross-section. Photoinitiated polymerization, such as thiol click chemistry, is well suited for rapidly solidifying the core fluid into a microfiber with predetermined size and shape.
A “sheath” fluid passing through a microfluidic channel at low Reynolds number can be directed around another “core” stream and used to dictate the shape as well as the diameter of a core stream. Grooves in the top and bottom of a microfluidic channel were designed to direct the sheath fluid and shape the core fluid. By matching the viscosity and hydrophilicity of the sheath and core fluids, the interfacial effects are minimized and complex fluid shapes can be formed. Controlling the relative flow rates of the sheath and core fluids determines the cross-sectional area of the core fluid. Fibers have been produced with sizes ranging from 300 nm to ~1 mm, and fiber cross-sections can be round, flat, square, or complex as in the case with double anchor fibers. Polymerization of the core fluid downstream from the shaping region solidifies the fibers. Photoinitiated click chemistries are well suited for rapid polymerization of the core fluid by irradiation with ultraviolet light. Fibers with a wide variety of shapes have been produced from a list of polymers including liquid crystals, poly(methylmethacrylate), thiol-ene and thiol-yne resins, polyethylene glycol, and hydrogel derivatives. Minimal shear during the shaping process and mild polymerization conditions also makes the fabrication process well suited for encapsulation of cells and other biological components.
Tissue scaffolds1, composite materials2, optical communications3, and conductive hybrid materials4 are areas of research utilizing specialized polymer fibers. Conventional methods for fiber fabrication include melt extrusion, spinning, drawing, casting and electrospinning. Most of the polymer fibers produced by these methods exhibit round cross-sections engendered by surface tension between the polymer and air during fabrication. However, fibers with nonround cross-sections may enhance the mechanical properties of composite materials5,6, increase surface area-to-volume ratios, control wetting or wicking7, and be utilized as waveguides8 or polarizers9.
Production of specialized polymer fibers by microfluidic systems employing one stream (sheath flow) to surround and shape another stream (core flow) are appealing because of the mild conditions and capacity for continuous production of highly reproducible fibers. Initial experiments produced round fibers with sizes dependent on the relative flow rates of the prepolymer and sheath fluids10-12. The discovery that grooves in the top and bottom of the microfluidic channel could deflect the sheath to produce a predetermined shape for the core stream13,14 led to technology for generating more complex fiber shapes10-12,15-17.
NRL investigators have demonstrated the following critical technical features13-21:
When fabricating polymer fibers using hydrodynamic focusing by a sheath stream to shape a prepolymer stream, selection of polymer materials is a practical first step. The appropriate polymers, corresponding initiator chemistries, and sheath fluids should be identified within the following guidelines:
After the materials have been selected, a microchannel to generate the desired fiber shape and size must be designed. To determine the required shaping features (stripes, herringbones, chevrons), computational fluid dynamics software can be utilized to predict the fluid flow patterns. The shaping features transport the sheath fluid around the core fluid. In general, stripes move the sheath fluid across the top and bottom of the channel from one side to the other, whereas herringbones and chevrons move the fluid away from the sides toward the top and/or bottom of the channel and then back toward the center of the channel directly under the point of the structure. The number of repetitive grooves in the top and bottom of the channel impacts the degree to which the sheath fluid is directed. The ratio of flow rates of the core and sheath fluid also mediate the effect. Simulations using COMSOL Multiphysics software have proven reliable in evaluating the interactions of the shaping features and flow-rate ratios to predict the cross-sectional shape. These simulations also provide useful insight into diffusion of solutes between the core and sheath with the size of the channel, viscosity, and flow rates proposed.
If a complex shape is desired, such as the “double anchor” described in Boyd et al.23, it is useful to separate the functions of shaping and sizing. A complex shape can be created with one set of features and then a strategically placed single-groove structure placed at the entrance of a second sheathing stream can be used to decrease the cross-sectional area of the polymerizable stream without significantly altering its shape.
Another example of complex microchannel design can generate multilayer fibers. In this design, sequential sets of shaping features and additional cladding fluids are introduced. These concentric flows can be solidified into solid core-cladding fibers or hollow tubes. An example of this device will be presented below.
Once the design of the microfluidic device has been chosen, the microchannel fabrication process can begin. Fabrication tools that can be used include soft lithography, CNC milling, hot embossing and 3D printing. Regardless of the tools used, it is important to realize that features accidently introduced into the wall of the microfluidic channel will also direct the sheath flow and may result in highly reproducible deviations in the cross-sectional shape of all fibers made using that device. Microchannel substrate materials should also be carefully selected to be physically robust, chemically inert, and resistant to UV-damage. For example, polydimethylsiloxane (PDMS) can be easily cast, provides gasket-like seals, and is UV transparent; PDMS is useful for the transparent top of the channel, but not the sides and bottom of the channel, which need more rigidity.
Ultimately, by introducing the properly selected core and sheath fluids at the flow rates predicted by the fluid dynamics simulations, the shaping features will generate the appropriate fluid profile and the downstream UV curing lamp will solidify the designed polymer fibers. Continuous extrusion of the polymerized fibers from the channel can provide reproducible fibers in lengths limited only by the volume of the fluid reservoirs.
This protocol describes the fabrication of a hollow fiber using photoinitiated thiol-yne click chemistry. The microchannel has chevron grooves or “stripes” as shaping features in the bottom and top of the channel (Figure 1). Three fluids are introduced and are directed in concentric streams; from the inner to outer fluid streams, these are referred to as the core, cladding, and sheath fluid. Only the cladding flow is polymerized to form the hollow fiber. The materials selected are as follows:
The microchannel device was assembled from aluminum and plastic parts fabricated by CNC milling and PDMS casting. Flow through the microchannel was controlled by three syringe pumps.
1. Design and Simulation of Microchannel
When calculating both fluid velocity and convection/diffusion within the microchannel, it is critical to assign the proper viscosity to each incoming fluid.
From the computational results, the required number and type of shaping features can be predicted to attain the desired fiber shape. The fluid flow rate inputs will also correlate to the required flow rates for generating the fibers. With these predictions, a microchannel device can be fabricated for the extrusion of polymer fibers.
2. Fabrication of Sheath Flow Apparatus Components
A combination of direct micromilling, hot-embossing, and/or polymer casting can be used to create the components of the sheath flow device. Depending on the resources, choose the strategy accordingly. The example presented is a direct milling process that uses a Computer Numerical Code (CNC). There are five layers to be made (from top to bottom), which are depicted in Figure 2: 1. Inlet chuck (aluminum), 2. Fastening plate (aluminum), 3. Microchannel top layer (cyclic olefin copolymer, COC or PDMS), 4. Microchannel bottom layer (COC or polyether ether ketone, PEEK), 5. Fastening plate (aluminum). (Example files for direct milling are available in *.stl format in the Supporting Information)
3. Sheath Flow Apparatus Assembly
4. Solution Preparation
As indicated earlier, many materials can be used to create microfibers using analogous protocols and sheath flow systems, but thiol-yne chemistry is used here. Prepare the prepolymer solution immediately before beginning the fiber extrusion process to avoid the increase in viscosity that may occur over time in storage.
5. Microfiber Production (Focus of Video)
A simple 2-stage design, using shaping grooves and three solution inputs, was used to create hollow fibers (Figure 1). COMSOL simulations were used to determine the appropriate flow-rate ratios to obtain the desired cross sectional size (Figure 1, ESI Video). A combination of milling and molding produced the components for the sheath flow assembly to fabricate the fibers (Figure 2). The complete assembly included the sheath flow device, fiber optic-coupled UV laser, three syringe pumps, a collection bath (beaker), and a fiber collection spool (Figure 3).
Polymerization of the cladding material was initiated by the UV light source, and hollow fibers were extruded from the microchannel into the collection bath. The fiber formed and was collected continuously until the UV light was turned off. The production of fibers continued for minutes and generated a single fiber over a meter in length. Fibers made under these conditions were approximately 200 µm in diameter. The structure of the fibers was visualized using optical and electron microscopy. The fibers had an oval shape with a hollow core. Capillary action was used to introduce liquid and bubbles into the interior of the fiber and confirmed that the hollow structure was continuous over the length of the fiber (Figure 4A).
Figure 1. Sheath flow device design and COMSOL data. The two-section fabrication device with straight grooves was selected to produce a hollow fiber (rotated about the x-axis 45°). The COMSOL simulations at left demonstrate how the core:cladding:sheath flow-rate ratios (numbers below each simulation) impact the final size of the hollow fibers. The microchannel cross-section is 1 mm x 0.75 mm, and the stripes are 0.38 mm wide and 250 µm deep. The stripes are at a ∠45° relative to the channel.
Figure 2. Exploded view of sheath flow assembly. From top to bottom, (A) inlet chuck, (B) fastening plate, (C) microchannel cover, (D) microchannel base, (E) fastening plate. The components are fabricated from aluminum, aluminum, COC (or PDMS), COC (or PEEK) and aluminum, respectively. The regularly spaced holes accommodate assembly screws.
Figure 3. Photo of layout and schematic overview. Setup includes sheath flow assembly secured vertically over beaker containing water bath, fiber optic laser for photopolymerization, three syringe pumps, and spindle for collecting polymer fibers. Inset shows fabrication assembly with UV illumination. (A) Sheath and core inlets, (B) microfluidic channel, (C) UV light, (D) collection reservoir, (E) polymerized fiber being collected.
Figure 4. Optical and scanning electron micrograph images of fibers made using hydrodynamic focusing. Fibers have been fabricated in the following shapes using hydrodynamic focusing: (A) Hollow tubes, (B) Rectangular ribbons, (C) Thin elastic ribbons, (D) Triangles, (E) Kidney beans, (F) String of pearls, (G) Round fiber with embedded carbon nanofiber, and (H) Double anchor shaped. The fibers are made of various materials including acrylates, methacrylates and thiol-enes.
ESI Video. Slice plot produced in COMSOL Multiphysics depicting one half of microchannel with core, cladding, and sheath fluids entering the device and traversing the two-stage flow-altering diagonal stripe grooves. The core, cladding, and sheath flow rates simulated are 1, 28, and 256 µl/min, respectively. The video represents ~6 sec in real-time, slowed down 6-fold for illustrative purposes.
Fabrication of polymer fibers using the sheath flow approach has multiple advantages in comparison to other fiber fabrication techniques. One of those advantages is the ability to fabricate fibers using various reagent combinations. Although a specific thiol-yne combination was presented here, several other thiol click (including thiol-ene) chemistry combinations work equally well. A wide variety of other combinations can be employed to produce fibers as long as the sheath solution is miscible with the core material to be polymerized. Inclusions such as nanofibers, particles, and cells are also possible as long as the contributions of these additives to the viscosity of the prepolymer solution are taken into account.
Thiol click chemistry is a subset of the click chemistry family in which a complex with a thiol group can be covalently attached to a complex with either an alkene (double bond) or alkyne (triple bond) functional group by UV light photopolymerization. Reactions involving alkenes are termed thiol–ene reactions, and reactions involving alkynes are termed thiol–yne reactions. One pi bond (from an alkene or alkyne) will attach to one thiol group upon UV light irradiation. The process fits well within the click family of reactions and has been effectively used in our microfluidic channel to produce fibers of various shapes (e.g. round, ribbon-shaped, double anchor) from numerous thiol click starting components.
A specific advantage to the method outlined here in comparison to most other similar processes is the ability to control both the shape and the size of the fibers produced (Figures 4A-H). By designing a channel to have stripes, chevrons, or herringbones, the fiber produced will have a different cross-section shape. In general, the stripes are useful for producing round shapes or for introduction of additional sheath streams to completely encircle previously shaped streams and move them away from the channel walls prior to polymerization. The chevrons reduce the vertical dimension in the center of the shaped stream, maintaining the horizontal symmetry. The herringbones reduce the vertical dimension of one side of the shaped stream, producing asymmetry. These shaping tools can be mixed in innumerable combinations. The number of equivalent features (i.e. 7 chevrons versus 10 chevrons) can also be used to produce fibers with different cross-sectional profiles.
In addition to the ability to control fiber shape, the fiber fabrication methodology presented also affords the ability to control the size of the fibers fabricated, even using a single sheath flow assembly (e.g. Figure 1). Adjusting the sheath:core flow-rate ratio is one means of fabricating fibers with different cross-sectional areas. It is also possible to control the size of the fiber by adjusting the channel design to have additional sheathing stages. Whether the shaping occurs in one or more stages, a simple final stage can be used to reduce the size of the core without changing the shape.
The ease with which a multitude of reagent combinations can be used to produce fibers of various shapes and sizes using this microfluidic channel design will prove useful in a wide range of applications, from tissue engineering to optical communications to smart textiles.
The authors have nothing to disclose.
Darryl A. Boyd and Michael A. Daniele are National Research Council Postdoctoral Fellows. The work was supported by ONR/NRL Work Units 4286 and 9899. The views are those of the authors and do not represent the opinion or policy of the US Navy or Department of Defense.
Pentaerythritol tetrakis 3-mercaptopropionate | Sigma-Aldrich | 381462 | See references |
1.7-Octadiyne | Sigma-Aldrich | 161292 | See references |
2,2-Dimethoxy-2-phenylacetophenone | Sigma-Aldrich | 196118 | See references |
Polyethylene glycol 400 | Sigma-Aldrich | 202398 | Polyethylene glycol 200 or 600, dextrose, or glycerol may be substituted |
Sylgard 184 | Sigma-Aldrich | 761036 | QSIL 216, OptiTec 7020, or GS RTV 615 may be substituted |
Table of Specific Equipment | |||
Equipment | Company | Catalogue number | Comments |
MiniMill | Haas | MINIMILL | Any NC code interpreting 2.5 axis (or higher) mill may be substituted |
Syringe pumps (3) | Harvard Apparatus | 702212 | Syringe pumps that can be programmed to deliver the desired volume flow rates may be substituted |
Tygon tubing (3 m) | Fisher Scientific | 14-169-13A | NA |
PEEK tubing | Upchurch Scientific | 1435 | NA |
HPLC fittings | Upchurch Scientific | 1457 | NA |
BlueWave 200 UV lamp with stand and light guides | Dymax | 38905; 38477; 39700 | Any guided UV source that delivers 300-450 nm, >200 mW/cm2 may be substituted |
500 ml beaker | Fisher Scientific | FB-100-600 | Any vessel of approximately the same size and shape may be substituted |
Ring stand | Fisher Scientific | S47807 | Any ring stand capable of mounting a clamped sheath flow apparatus above the level of the syringe pumps may be substituted |
Ring stand clamp holder (2) | Fisher Scientific | S02625 | Any ring stand clamp holder capable of holding the clamps may be substituted |
Ring stand clamps (2) | Fisher Scientific | 02-216-352 | Any ring stand clamp capable of holding the clamped sheath flow apparatus and light guides may be substituted |
1, 5, and 60 ml Syringes | Fisher Scientific | 14-823-16H; 14-823-16D; 14-820-11 | Any syringe with known inner diameter and sufficient volume may be substituted |
Poly(methylmethacrylate) (3.2 mm) | McMaster-Carr | 8560K239 | Polycarbonate and cyclic olefin copolymer may be substituted |
Polyether ether ketone (3.2 mm) | McMaster-Carr | 8504K25 | Solvent resistant machinable materials may be substituted |
Aluminum (3.2, 9.5 mm) | McMaster-Carr | 1651T41; 9246K23 | Substitute other materials as needed |