An Acoustofluidic Capillary Nozzle for Programmable Microstructure Assembly in Direct Ink Writing of Flexible...

The spatial organization of microscale fillers is critical for macroscopic performance, yet precise control over their distribution and orientation remains a major challenge in direct ink writing. Here, we present an acoustofluidic capillary nozzle that integrates acoustic manipulation into direct ink writing, enabling programmable in situ assembly of functional fillers during extrusion. By coupling a piezoelectric transducer with a commercial glass capillary, stable acoustic standing waves are established within the flow channel, driving suspended filler particles toward pressure nodes via acoustic radiation forces. Simulations and experiments systematically investigate how capillary geometry and material properties influence acoustic energy distribution and particle assembly behavior. In particular, rectangular capillaries generate stable multi-node standing waves, inducing periodic alignment of nickel-coated carbon fibers into ordered conductive bundles. This acoustically programmed microstructure reduces the percolation threshold from 8 wt% to 2 wt% and enhances electrical conductivity by up to 32.1-fold at identical filler contents. Meanwhile, the composites exhibit pronounced anisotropic conductivity and maintain excellent mechanical flexibility, with stable electromechanical performance under 16% bending strain and cyclic loading. This work demonstrates a simple and scalable acoustofluidic nozzle platform for programmable microstructure engineering in direct ink writing, offering new opportunities for fabricating high-performance multifunctional composites.