Microfluidic Assembly of Microblocks into Interlocked Structures for Enhanced Strength and Toughness

Compared with monolithic materials, topologically interlocked materials (TIMs) exhibit higher toughness based on their enhanced crack deflection and deformation tolerance. Importantly, by reducing the block size of TIMs, their structural strength can also be improved due to the reduced flexural span. However, the assembly of microscale blocks remains a huge challenge due to the inadequacy of nanoscale self-assembly or macroscale pick-and-place operations. In this work, octahedral microblocks are fabricated and constructed into interlocked structures with different patterns through microfluidic channels with variable cross sections. The pattern of the interlocked panel is demonstrated to affect its strength and toughness. The failure strength and energy absorption of assembled panels significantly exceed that of their monolithic counterpart by ∼33% and ∼19.1 folds, respectively. Generally, the presented microfluidic method provides a unique technique for the assembly of interlocked architecture, which facilitates the design and fabrication of TIMs with highly improved strength and toughness.