Resolving optical illumination distributions along an axially symmetric photodetecting fiber

Thermally Drawn Elastomer Nanocomposites for Soft Mechanical Sensors

Stretchable and conductive nanocomposites are emerging as important constituents of soft mechanical sensors for health monitoring, human-machine interactions, and soft robotics. However, tuning the materials' properties and sensor structures to the targeted mode and range of mechanical stimulation is limited by current fabrication approaches, particularly in scalable polymer melt techniques. Here, thermoplastic elastomer-based nanocomposites are engineered and novel rheological requirements are proposed for their compatibility with fiber processing technologies, yielding meters-long, soft, and highly versatile stretchable fiber devices. Based on microstructural changes in the nanofiller arrangement, the resistivity of the nanocomposite is tailored in its final device architecture across an entire order of magnitude as well as its sensitivity to strain via tuning thermal drawing processing parameters alone. Moreover, the prescribed electrical properties are coupled with suitable device designs and several fiber-based sensors are proposed aimed at specific types of deformations: i) a robotic fiber with an integrated bending mechanism where changes as small as 5° are monitored by piezoresistive nanocomposite elements, ii) a pressure-sensing fiber based on a geometrically controlled resistive signal that responds with a sub-newton resolution to changes in pressing forces, and iii) a strain-sensing fiber that tracks changes in capacitance up to 100% elongation.

100 m Long Thermally Drawn Supercapacitor Fibers with Applications to 3D Printing and Textiles

Supercapacitor fibers, with short charging times, long cycle lifespans, and high power densities, hold promise for powering flexible fabric-based electronics. To date, however, only short lengths of functioning fiber supercapacitors have been produced. The primary goal of this study is to introduce a supercapacitor fiber that addresses the remaining challenges of scalability, flexibility, cladding impermeability, and performance at length. This is achieved through a top-down fabrication method in which a macroscale preform is thermally drawn into a fully functional energy-storage fiber. The preform consists of five components: thermally reversible porous electrode and electrolyte gels; conductive polymer and copper microwire current collectors; and an encapsulating hermetic cladding. This process produces 100 m of continuous functional supercapacitor fiber, orders of magnitude longer than any previously reported. In addition to flexibility (5 mm radius of curvature), moisture resistance (100 washing cycles), and strength (68 MPa), these fibers have an energy density of 306 μWh cm^-2 at 3.0 V and ≈100% capacitance retention over 13 000 cycles at 1.6 V. To demonstrate the utility of this fiber, it is machine-woven and used as filament for 3D printing.

Recent Progress and Perspectives of Thermally Drawn Multimaterial Fiber Electronics

Fibers are the building blocks of a broad spectrum of products from textiles to composites, and waveguides to wound dressings. While ubiquitous, the capabilities of fibers have not rapidly increased compared to semiconductor chip technology, for example. Recognizing that fibers lack the composition, geometry, and feature sizes for more functions, exploration of the boundaries of fiber functionality began some years ago. The approach focuses on a particular form of fiber production, thermal-drawing from a preform. This process has been used for producing single material fibers, but by combining metals, insulators, and semiconductors all within a single strand of fiber, an entire world of functionality in fibers has emerged. Fibers with optical, electrical, acoustic, or optoelectronic functionalities can be produced at scale from relatively easy-to-assemble macroscopic preforms. Two significant opportunities now present themselves. First, can one expect that fiber functions escalate in a predictable manner, creating the context for a "Moore's Law" analog in fibers? Second, as fabrics occupy an enormous surface around the body, could fabrics offer a valuable service to augment the human body? Toward answering these questions, the materials, performance, and limitations of thermally drawn fibers in different electronic applications are detailed and their potential in new fields is envisioned.

Structured multimaterial filaments for 3D printing of optoelectronics

Simultaneous 3D printing of disparate materials; metals, polymers and semiconductors with device quality interfaces and at high resolution remains challenging. Moreover, the precise placement of discrete and continuous domains to enable both device performance and electrical connectivity poses barriers to current high-speed 3D-printing approaches. Here, we report filaments with disparate materials arranged in elaborate microstructures, combined with an external adhesion promoter, to enable a wide range of topological outcomes and device-quality interfaces in 3D printed media. Filaments, structured towards light-detection, are printed into fully-connected 3D serpentine and spherical sensors capable of spatially resolving light at micron resolution across its entire centimeter-scale surface. 0-dimensional metallic microspheres generate light-emitting filaments that are printed into hierarchical 3D objects dotted with electroluminescent pixels at high device resolution of 55 µm not restricted by surface tension effects. Structured multimaterial filaments provides a path towards custom three-dimensional functional devices not realizable by existing approaches.

Microstructured Fibers for the Production of Food

Food engineering faces the difficult challenge of combining taste, i.e., tailoring texture and rheology of food matrices with the balanced intake of healthy nutrients. In materials science, fiber suspensions and composites have been developed as a versatile and successful approach to tailor rheology while imparting materials with added functionalities. Structures based on such types of physical (micro)fibers are however rare in food production mainly due to a lack of food-grade materials and processes allowing for the fabrication of fibers with controlled sizes and microstructures. Here, the controlled fabrication of multi-material microstructured edible fibers is demonstrated using a food compatible process based on preform-to-fiber thermal drawing. It is shown that different material systems based on gelatin or casein, with plasticizers such as glycerol, can be thermally drawn into fibers with various geometries and cross-sectional structures. It is demonstrated that fibers can exhibit tailored mechanical properties post-drawing, and can encapsulate nutrients to control their release. The versatility of fiber materials is also exploited to demonstrate the fabrication of food-grade fabrics and scaffolds for food growth. The end results establish a new field in food production that relies on fiber-based simple and eco-friendly processes to realize enjoyable yet healthy and nutritious products.

Flexible fiber-based optoelectronics for neural interfaces

Neurological and psychiatric conditions pose an increasing socioeconomic burden on our aging society. Our ability to understand and treat these conditions relies on the development of reliable tools to study the dynamics of the underlying neural circuits. Despite significant progress in approaches and devices to sense and modulate neural activity, further refinement is required on the spatiotemporal resolution, cell-type selectivity, and long-term stability of neural interfaces. Guided by the principles of neural transduction and by the materials properties of the neural tissue, recent advances in neural interrogation approaches rely on flexible and multifunctional devices. Among these approaches, multimaterial fibers have emerged as integrated tools for sensing and delivering of multiple signals to and from the neural tissue. Fiber-based neural probes are produced by thermal drawing process, which is the manufacturing approach used in optical fiber fabrication. This technology allows straightforward incorporation of multiple functional components into microstructured fibers at the level of their macroscale models, preforms, with a wide range of geometries. Here we will introduce the multimaterial fiber technology, its applications in engineering fields, and its adoption for the design of multifunctional and flexible neural interfaces. We will discuss examples of fiber-based neural probes tailored to the electrophysiological recording, optical neuromodulation, and delivery of drugs and genes into the rodent brain and spinal cord, as well as their emerging use for studies of nerve growth and repair.

Advanced Multimaterial Electronic and Optoelectronic Fibers and Textiles

The ability to integrate complex electronic and optoelectronic functionalities within soft and thin fibers is one of today's key advanced manufacturing challenges. Multifunctional and connected fiber devices will be at the heart of the development of smart textiles and wearable devices. These devices also offer novel opportunities for surgical probes and tools, robotics and prostheses, communication systems, and portable energy harvesters. Among the various fiber-processing methods, the preform-to-fiber thermal drawing technique is a very promising process that is used to fabricate multimaterial fibers with complex architectures at micro- and nanoscale feature sizes. Recently, a series of scientific and technological breakthroughs have significantly advanced the field of multimaterial fibers, allowing a wider range of functionalities, better performance, and novel applications. Here, these breakthroughs, in the fundamental understanding of the fluid dynamics, rheology, and tailoring of materials microstructures at play in the thermal drawing process, are presented and critically discussed. The impact of these advances on the research landscape in this field and how they offer significant new opportunities for this rapidly growing scientific and technological platform are also discussed.

Superelastic Multimaterial Electronic and Photonic Fibers and Devices via Thermal Drawing

Electronic and photonic fiber devices that can sustain large elastic deformation are becoming key components in a variety of fields ranging from healthcare to robotics and wearable devices. The fabrication of highly elastic and functional fibers remains however challenging, which is limiting their technological developments. Simple and scalable fiber-processing techniques to continuously codraw different materials within a polymeric structure constitute an ideal platform to realize functional fibers and devices. Despite decades of research however, elastomeric materials with the proper rheological attributes for multimaterial fiber processing cannot be identified. Here, the thermal drawing of hundreds-of-meters long multimaterial optical and electronic fibers and devices that can sustain up to 500% elastic deformation is demonstrated. From a rheological and microstructure analysis, thermoplastic elastomers that can be thermally drawn at high viscosities (above 10³ Pa s), allowing the encapsulation of a variety of microstructured, soft, and rigid materials are identified. Using this scalable approach, fiber devices combining high performance, extreme elasticity, and unprecedented functionalities, allowing novel applications in smart textiles, robotics, or medical implants, are demonstrated.

Optoelectronic Fibers via Selective Amplification of In-Fiber Capillary Instabilities

Thermally drawn metal-insulator-semiconductor fibers provide a scalable path to functional fibers. Here, a ladder-like metal-semiconductor-metal photodetecting device is formed inside a single silica fiber in a controllable and scalable manner, achieving a high density of optoelectronic components over the entire fiber length and operating at a bandwidth of 470 kHz, orders of magnitude larger than any other drawn fiber device.

All-in-fiber chemical sensing

A new all-in-fiber trace-level chemical sensing approach is demonstrated. Photoconductive structures, embedded directly into the fiber cladding along its entire length, capture light emitted anywhere within the fiber's hollow core and transform it directly into an electrical signal. Localized signal transduction circumvents problems associated with conventional fiber-optics, including limited signal collection efficiency and optical losses. This approach facilitates a new platform for remote and distributed photosensing.