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bioRxiv · 10.1101/2025.10.27.684743

3D Hydrodynamic Flow Lithography

Zou, Y.·Sahin, M. A.·Khan, M. Z. U.·Akhtar, M. U.·Destgeer, G.
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Abstract

Continuous- and stop-flow lithography has been widely used for the fabrication of ingenious multi-dimensional microstructures, including fibers and microparticles. The flow profile of multiple co-flowing streams during the process, as one of the dimensions, dictates the cross-sectional morphology of the microstructures. Here, we introduce a three-dimensional hydrodynamic flow lithography (3D HFL) approach that enables rapid and programmable generation of desired flow profiles and their conversion into solid microstructures. By strategically combining multiple flow sculpting strategies, including variable inlet configurations, intra-channel pillar configurations, and outlet configurations, we achieved precise and versatile control over flow sculpting, as validated by computational fluid dynamics simulations and experimental production of microparticles and fibers, offering unparalleled design flexibility. Importantly, the flow sculpting device is fabricated using low-cost 3D-printed molds to cast PDMS channels with precisely aligned inlets and complex geometries that are difficult or impossible to achieve using conventional soft lithography. Our 3D HFL approach effectively overcomes the limitations of existing microfabrication techniques in device complexity, structural diversity, multi-material integration, and production throughput. Furthermore, we demonstrated the capability of this platform to produce anisotropic multi-material microparticles and fibers tailored for specific applications, such as amphiphilic particles for uniform microdroplet capture, biocompatible patterned hydrogels for controlled cell adhesion, and dual-layer fibers for temperature sensing. The simplicity of device fabrication, combined with the broad design flexibility, establishes this platform as a scalable, high-throughput, and versatile solution for engineering anisotropic microparticles and fibers with tailored functionalities, providing powerful tools for a wide range of downstream fields.

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Zou, Y., Sahin, M. A., Khan, M. Z. U., Akhtar, M. U., Destgeer, G.. 2025-10-28. 3D Hydrodynamic Flow Lithography. https://doi.org/10.1101/2025.10.27.684743

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