For successful material deployment in tissue engineering, the material itself, its mechanical properties, and the microscopic geometry of the product are of particular interest. While silk is a widely applied protein-based tissue engineering material with strong mechanical properties, the size and shape of artificially spun silk fibers are limited by existing processes. This study adjusts a microfluidic spinneret to manufacture micron-sized wet-spun fibers with three different materials enabling diverse geometries for tissue engineering applications. The spinneret is direct laser written (DLW) inside a microfluidic polydimethylsiloxane (PDMS) chip using two-photon lithography, applying a novel surface treatment that enables a tight print-channel sealing. Alginate, polyacrylonitrile, and silk fibers with diameters down to 1 μm are spun, while the spinneret geometry controls the shape of the silk fiber, and the spinning process tailors the mechanical property. Cell-cultivation experiments affirm bio-compatibility and showcase an interplay between the cell-sized fibers and cells. The presented spinning process pushes the boundaries of fiber fabrication toward smaller diameters and more complex shapes with increased surface-to-volume ratio and will substantially contribute to future tailored tissue engineering materials for healthcare applications.
Today, millimeter‐sized nonspherical any‐shape particles serve as flexible, functional scaffold material in chemical and biochemical reactors tailoring their hydrodynamic properties and active surface‐to‐volume ratio based on the particle's shape. Decreasing the particle size to smaller than 100 μm would be desired as it increases the surface‐to‐volume ratio and promotes a particle assembly based on surface interactions, allowing the creation of tailored self‐assembling 3D scaffolds. This study demonstrates a continuous high‐throughput fabrication of microscopic 3D particles with complex shape and sub‐micron resolution using continuous two‐photon vertical flow lithography. Evolving from there, in‐channel particle fabrication into a confined microfluidic chamber with a resting fluid enables the precise fabrication of a defined number of particles. 3D assemblies with various particle shapes are fabricated and analyzed regarding their permeability and morphology, representing convective accessibility of the assembly's porosity. Differently shaped particles highlight the importance of contact area regarding particle–particle interactions and the respective hydraulic resistance of an assembly. Finally, cell culture experiments show manifold cell–particle interactions promising applicability as bio‐hybrid tissue. This study pushes the research boundaries of adaptive, responsive, and permeable 3D scaffolds and granular media by demonstrating a high throughput fabrication solution and a precise hydrodynamic analysis method for micro‐particle assemblies.
The filtration performance of soft colloid suspensions suffers from the agglomeration of the colloids on the membrane surface as filter cakes. Backflushing of fluid through the membrane and cross-flow flushing across the membrane are widely used methods to temporally remove the filter cake and restore the flux through the membrane. However, the phenomena occurring during the recovery of the filtration performance are not yet fully described. In this study, we filtrate poly(N-isopropylacrylamide) microgels and analyze the filter cake in terms of its composition and its dynamic mobility during removal using on-line laser scanning confocal microscopy. First, we observe uniform cake build-up that displays highly ordered and amorphous regions in the cake layer. Second, backflushing removes the cake in coherent pieces and their sizes depend on the previous cake build-up. And third, cross-flow flushing along the cake induces a pattern of longitudinal ridges on the cake surface, which depends on the cross-flow velocity and accelerates cake removal. These observations give insight into soft colloid filter cake arrangement and reveal the cake’s unique behaviour exposed to shear-stress.
Filter cake formation is the predominant phenomenon limiting the filtration performance of membrane separation processes. However, the filter cake’s behavior at the particle scale, which determines its overall cake behavior, has only recently come into the focus of scientists, leaving open questions about its formation and filtration behavior. The present study contributes to the fundamental understanding of soft filter cakes by analyzing the influence of the porous membrane’s morphology on crystal formation and the compaction behavior of soft filter cakes under filtration conditions. Microfluidic chips with nanolithographic imprinted filter templates were used to trigger the formation of crystalline colloidal filter cakes formed by soft microgels. The soft filter cakes were observed via confocal laser scanning microscopy (CLSM) under dead-end filtration conditions. Colloidal crystal formation in the cake, as well as their compaction behavior, were analyzed by optical visualization and pressure data. For the first time, we show that exposing the soft cake to a crystalline filter template promotes the formation of colloidal crystallites and that soft cakes experience gradient compression during filtration.
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