A jet-assisted wet spinning system for manufacturing and shaping photopolymerizable microfibers with precise control

Background

The field of fiber manufacturing, particularly for advanced applications such as biomaterials, textiles, and optical devices, has seen significant interest in producing fibers with precise dimensions and tailored geometries. Photopolymerizable materials are especially attractive due to their ability to be rapidly solidified and patterned using light, enabling the fabrication of complex structures suitable for biomedical scaffolds, smart textiles, and micro-optical components. However, as the demand for finer, more versatile fibers grows, so does the need for manufacturing techniques that can reliably produce fibers with controlled diameters, diverse shapes, and scalable throughput, all while maintaining compatibility with sensitive or functional materials.

Current approaches to fiber production face notable challenges when applied to photopolymerizable materials. Traditional wet spinning relies on mechanical drawing to achieve fine diameters, but this method is not compatible with materials that require photopolymerization, as the drawing process can disrupt or preclude uniform light exposure and curing. Microfluidic wet spinning offers improved diameter control but is plagued by clogging issues, as the solidification of the precursor within narrow channels can block flow and halt production. These limitations hinder scalability, restrict the range of achievable fiber geometries, and complicate the manufacturing of fibers for advanced applications. As a result, there remains a critical need for a robust, scalable, and versatile fiber fabrication method that overcomes the drawbacks of mechanical drawing and microfluidic clogging, especially for photopolymerizable systems.

Technology

Jet Assisted Wet Spinning (JAWS) is an advanced fiber manufacturing technique that leverages a high-velocity liquid jet to elongate and thin a parallel stream of photopolymerizable precursor solution within a liquid bath. This fluid-driven acceleration enables the production of fibers with precisely controlled diameters, ranging from sub-10 microns to hundreds of microns, without the mechanical drawing or microchannel clogging issues seen in traditional or microfluidic wet spinning methods. After the precursor stream is thinned by the jet, it is solidified downstream using UV light, allowing for rapid photopolymerization. The system is highly adaptable: by adjusting parameters such as light intensity, nozzle oscillation, and bath chemistry, it can produce a variety of fiber geometries, including looped, hollow, or dumbbell shapes. Multiple precursor jets can be used in parallel for scalable production, and the process is compatible with a wide range of precursor and bath liquid combinations, making it suitable for applications in biomaterials, textiles, and optical devices.

What sets JAWS apart is its unique combination of precision, scalability, and versatility. Unlike conventional wet spinning, which relies on mechanical drawing and is incompatible with photopolymerizable materials, or microfluidic spinning, which suffers from clogging due to premature solidification, JAWS uses a fluidic approach that avoids these pitfalls. The method’s ability to control fiber diameter and geometry in real time—by tuning flow rates, light exposure, and mechanical oscillation—enables the fabrication of complex, application-specific fiber architectures. Additionally, the process is robust and scalable, requiring only reliable nozzle and support structures, and it supports the parallel production of multiple fibers. Experimental validation demonstrates the creation of entangled fiber networks with tunable mechanical properties, which can be concentrated during extrusion for applications such as injectable biomaterials and 3D printing. This comprehensive control over fiber formation and suspension behavior, combined with biocompatibility and industrial scalability, differentiates JAWS as a transformative solution for advanced fiber manufacturing.

Benefits

• Precise control of fiber diameter from sub-10 microns to hundreds of microns without mechanical drawing
• Elimination of clogging issues common in microfluidic wet spinning methods
• Capability to produce diverse fiber geometries (e.g., looped, hollow, dumbbell) by adjusting process parameters
• Scalable production through parallel operation of multiple jets
• Compatibility with photopolymerizable materials and biocompatibility for biomedical applications
• Robust and adaptable system design suitable for industrial manufacturing
• Enhanced control over fiber suspension concentration and porosity via poroelastic extrusion modeling
• Versatility for applications in biomaterials, textiles, optical devices, 3D printing, and material repair

Applications

• Biomedical scaffolds for tissue engineering
• Microstructured fibers for advanced textiles
• Injectable entangled fiber biomaterials
• Optical fiber fabrication
• 3D printing of fiber networks

Additional info

Jet Assisted Wet Spinning (JAWS) employs a high-velocity liquid jet to thin and elongate parallel streams of photopolymerizable precursor solution within a liquid bath. This fluid-driven acceleration enables precise diameter control—from sub-10 microns to hundreds of microns—while avoiding microchannel clogging. Downstream UV exposure solidifies the streams. By modulating light intensity, nozzle oscillation, or bath chemistry, the system produces complex geometries, including looped, hollow, or dumbbell-shaped microfibers.