Braiding, twisting, and weaving microscale fibers with capillary forces

Soft materials made from braided or woven microscale fibers can display unique properties that can be exploited in electromagnetic, mechanical, and biomedical applications. These properties depend on the topology of the braids or weaves-that is, the order in which fibers cross one another. Current industrial braiding and weaving machines cannot easily braid or weave micrometer-scale fibers into controllable topologies; they typically apply forces that are large enough to break the fibers, and each machine can typically make only one topology. Here we use a 3D-printed device called a "capillary machine" to manipulate micrometer-scale fibers without breaking them. The operating principle is the physics of capillary forces: as the machines move vertically, they exert lateral capillary forces on floating objects, which in turn move small fibers connected to them. We present a new type of capillary machine that is based on principles of braid theory. It implements all the possible fiber-swapping operations for a set of four fibers and can therefore make any four-strand topology, including braids, twists, hierarchical twists, and weaves. We make these different topologies by changing the pattern of vertical motion of the machine. This approach is a mechanically simple, yet versatile way to make micro- and nano-textiles. We describe the prospects and limitations of this new type of machine for applications.