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Microfluidic Capillary Arrays for Pixelated Control of Multimaterial Flows
Max Chapman1, Muhammad Utomo1, David J Collins1,2
1Department of Biomedical Engineering, University of Melbourne, Melbourne, Victoria, Australia.
Small (Weinheim an Der Bergstrasse, Germany)
|August 11, 2026
Summary
This study introduces a new method for creating custom microscale fluid flows using 3D-printed microfluidic capillaries. This technique allows for complex, arbitrary cross-sectional geometries, advancing microfluidic device capabilities.
Area of Science:
- Microfluidics
- Materials Science
- 3D Printing
- Fluid Dynamics
Background:
- Previous microfluidic flow control was limited to simple, axisymmetric geometries.
- Achieving complex, arbitrary cross-sections for heterogeneous flows was a significant challenge.
Purpose of the Study:
- To develop a novel, scalable approach for producing customizable microscale multimaterial flow cross-sections.
- To enable the creation of arbitrary fluidic geometries beyond radial symmetries.
Main Methods:
- Utilizing a 3D-printed array of microfluidic capillaries to precisely control fluid inputs.
- Employing viscosity-matched fluids to dictate heterogeneous Poiseuille flow cross-sections.
- Developing an automated algorithm for designing and 3D printing integrated flow extruder manifolds.
- Leveraging laminar flow conditions for resolution amplification of microscale features.
Main Results:
- Demonstrated the production of complex, non-axisymmetric multimaterial flow geometries.
- Achieved effective resolution amplification of two orders of magnitude beyond the 3D printing minimum feature size.
- Successfully produced hydrogel microfibers using up to 2347 individually defined fluidic pixels.
- Showcased spatial tuneability with periodic and asymmetric flow patterns.
Conclusions:
- The novel approach enables arbitrary microscale flow cross-section definition with high precision.
- This technology has significant potential for optofluidics, biofabrication, and lab-on-a-chip applications.
- The method offers scalability and customization for advanced microfluidic systems.
