Microfluidic-assisted fiber production: Potentials, limitations, and prospects

Besides the conventional fiber production methods, microfluidics has emerged as a promising approach for the engineered spinning of fibrous materials and offers excellent potential for fiber manufacturing in a controlled and straightforward manner. This method facilitates low-speed prototype synthesis of fibers for diverse applications while providing superior control over reaction conditions, efficient use of precursor solutions, reagent mixing, and process parameters. This article reviews recent advances in microfluidic technology for the fabrication of fibrous materials with different morphologies and a variety of properties aimed at various applications. First, the basic principles, as well as the latest developments and achievements of microfluidic-based techniques for fiber production, are introduced. Specifically, microfluidic platforms made of glass, polymers, and/or metals, including but not limited to microfluidic chips, capillary-based devices, and three-dimensional printed devices are summarized. Then, fiber production from various materials, such as alginate, gelatin, silk, collagen, and chitosan, using different microfluidic platforms with a broad range of cross-linking agents and mechanisms is described. Therefore, microfluidic spun fibers with diverse diameters ranging from submicrometer scales to hundreds of micrometers and structures, such as cylindrical, hollow, grooved, flat, core-shell, heterogeneous, helical, and peapod-like morphologies, with tunable sizes and mechanical properties are discussed in detail. Subsequently, the practical applications of microfluidic spun fibers are highlighted in sensors for biomedical or optical purposes, scaffolds for culture or encapsulation of cells in tissue engineering, and drug delivery. Finally, different limitations and challenges of the current microfluidic technologies, as well as the future perspectives and concluding remarks, are presented.