A Microfluidic Digital Shutter of Liquid–Liquid Interface for Fabrication of Multifaceted Hydrogel Microfiber Structure

Abstract The digital logic elements based on microfluidic devices are proposed for complex fluidic control. However, there is no logic microfluidic device for fabrication. Moreover, the precise fabrication of anisotropic hydrogel microparticles with programmable geometries has long remained a central challenge in soft matter physics, materials science, and biomedical engineering. Here, a programmable passive digital shutter mechanism based on multiphase liquid–liquid interface dynamics is introduced for the precise fabrication of hydrogel microfibers in a microfluidic platform. There are three fluids in the devices, where two immiscible phases are designed for creating a digital shutter and two aqueous phases for hydrogel formation. It is found that the liquid bridge of hydrogel solution at the liquid–liquid interface has a critical stable length, and the digital shutter is achieved by toggling between liquid bridge maintenance and breakup. By modulating the digital shutter, deterministic control over geometry in terms of length, aspect ratio, curvature, and torsion, and produce microfibers in diverse shapes, including linear, helical, tadpole‐like, and spherical is achieved. To highlight its potential for tissue engineering, active materials, and soft microrobotics, the platform is utilized to generate cell‐laden microfibers with high resolution and viability, and magnetically responsive microfibers.