Self-shrinking soft demoulding for complex high-aspect-ratio microchannels

Dongliang Fan, Xi Yuan, Wenyu Wu, Renjie Zhu, Xin Yang, Yuxuan Liao, Yunteng Ma, Chufan Xiao, Cheng Chen, Changyue Liu, Hongqiang Wang () and Peiwu Qin ()
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Dongliang Fan: Southern University of Science and Technology
Xi Yuan: Institute of Biopharmaceutical and Health Engineering, Tsinghua Shenzhen International Graduate School
Wenyu Wu: Southern University of Science and Technology
Renjie Zhu: Southern University of Science and Technology
Xin Yang: Southern University of Science and Technology
Yuxuan Liao: Southern University of Science and Technology
Yunteng Ma: Southern University of Science and Technology
Chufan Xiao: Institute of Biopharmaceutical and Health Engineering, Tsinghua Shenzhen International Graduate School
Cheng Chen: National University of Singapore
Changyue Liu: Institute of Biopharmaceutical and Health Engineering, Tsinghua Shenzhen International Graduate School
Hongqiang Wang: Southern University of Science and Technology
Peiwu Qin: Institute of Biopharmaceutical and Health Engineering, Tsinghua Shenzhen International Graduate School

Nature Communications, 2022, vol. 13, issue 1, 1-11

Abstract: Abstract Microchannels are the essential elements in animals, plants, and various artificial devices such as soft robotics, wearable sensors, and organs-on-a-chip. However, three-dimensional (3D) microchannels with complex geometry and a high aspect ratio remain challenging to generate by conventional methods such as soft lithography, template dissolution, and matrix swollen processes, although they are widespread in nature. Here, we propose a simple and solvent-free fabrication method capable of producing monolithic microchannels with complex 3D structures, long length, and small diameter. A soft template and a peeling-dominant template removal process are introduced to the demoulding process, which is referred to as soft demoulding here. In combination with thermal drawing technology, microchannels with a small diameter (10 µm), a high aspect ratio (6000, length-to-diameter), and intricate 3D geometries are generated. We demonstrate the vast applicability and significant impact of this technology in multiple scenarios, including soft robotics, wearable sensors, soft antennas, and artificial vessels.

Date: 2022
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DOI: 10.1038/s41467-022-32859-z

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