Hydrogel-assisted microfluidic spinning of stretchable fibers via fluidic and interfacial self-adaptations

Stretchable polymeric fibers have enormous potential, but their production requires rigorous environmental controls and considerable resource consumption. It's also challenging for elastic polymers with high performance but poor spinnability, such as silicones like polydimethylsiloxane and Ecoflex. We present a hydrogel-assisted microfluidic spinning (HAMS) method to address these challenges by encapsulating their prepolymers within arbitrarily long, protective, and sacrificable hydrogel fibers. By designing simple apparatuses and manipulating the fluidic and interfacial self-adaptations of oil/water flows, we successfully produce fibers with widely controllable diameter (0.04 to 3.70 millimeters), notable length, high quality (e.g., smooth surface, whole-length uniformity, and rounded section), and remarkable stretchability (up to 1300%) regardless of spinnability. Uniquely, this method allows an easy, effective, and controllable reshaping production of helical fibers with exceptional stretchability and mechanical compliance. We deeply reveal the mechanisms in producing these fibers and demonstrate their potential as textile components, optoelectronic devices, and actuators. The HAMS method would be a powerful tool for mass-producing high-quality stretchable fibers.