Directed evolution of material-producing microorganisms.

Nature is home to a variety of microorganisms that create materials under environmentally friendly conditions. While this offers an attractive approach for sustainable manufacturing, the production of materials by native microorganisms is usually slow and synthetic biology tools to engineer faster microorganisms are only available when prior knowledge of genotype-phenotype links is available. Here, we utilize a high-throughput directed evolution platform to enhance the fitness of whole microorganisms under selection pressure and identify genetic pathways to enhance the material production capabilities of native species. Using Komagataeibacter sucrofermentans as a model cellulose-producing microorganism, we show that our droplet-based microfluidic platform enables the directed evolution of these bacteria toward a small number of cellulose overproducers from an initial pool of 40,000 random mutants. Sequencing of the evolved strains reveals an unexpected link between the cellulose-forming ability of the bacteria and a gene encoding a protease complex responsible for protein turnover in the cell. The ability to enhance the fitness of microorganisms toward a specific phenotype and to unravel genotype-phenotype links makes this high-throughput directed evolution platform a promising tool for the development of new strains for the sustainable manufacturing of materials.

Nacre-like composites with superior specific damping performance.

Biological materials such as nacre have evolved microstructural design principles that result in outstanding mechanical properties. While nacre's design concepts have led to bio-inspired materials with enhanced fracture toughness, the microstructural features underlying the remarkable damping properties of this biological material have not yet been fully explored in synthetic composites. Here, we study the damping behavior of nacre-like composites containing mineral bridges and platelet asperities as nanoscale structural features within its brick-and-mortar architecture. Dynamic mechanical analysis was performed to experimentally elucidate the role of these features on the damping response of the nacre-like composites. By enhancing stress transfer between platelets and at the brick/mortar interface, mineral bridges and nano-asperities were found to improve the damping performance of the composite to levels that surpass many biological and man-made materials. Surprisingly, the improved properties are achieved without reaching the perfect organization of the biological counterparts. Our nacre-like composites display a loss modulus 2.4-fold higher than natural nacre and 1.4-fold more than highly dissipative natural fiber composites. These findings shed light on the role of nanoscale structural features on the dynamic mechanical properties of nacre and offer design concepts for the manufacturing of bio-inspired composites for high-performance damping applications.

Three-dimensional printing of mycelium hydrogels into living complex materials.

Biological living materials, such as animal bones and plant stems, are able to self-heal, regenerate, adapt and make decisions under environmental pressures. Despite recent successful efforts to imbue synthetic materials with some of these remarkable functionalities, many emerging properties of complex adaptive systems found in biology remain unexplored in engineered living materials. Here, we describe a three-dimensional printing approach that harnesses the emerging properties of fungal mycelia to create living complex materials that self-repair, regenerate and adapt to the environment while fulfilling an engineering function. Hydrogels loaded with the fungus Ganoderma lucidum are three-dimensionally printed into lattice architectures to enable mycelial growth in a balanced exploration and exploitation pattern that simultaneously promotes colonization of the gel and bridging of air gaps. To illustrate the potential of such mycelium-based living complex materials, we three-dimensionally print a robotic skin that is mechanically robust, self-cleaning and able to autonomously regenerate after damage.

Three-dimensional printing of hierarchical liquid-crystal-polymer structures.

Fibre-reinforced polymer structures are often used when stiff lightweight materials are required, such as in aircraft, vehicles and biomedical implants. Despite their very high stiffness and strength1, such lightweight materials require energy- and labour-intensive fabrication processes2, exhibit typically brittle fracture and are difficult to shape and recycle3,4. This is in stark contrast to lightweight biological materials such as bone, silk and wood, which form by directed self-assembly into complex, hierarchically structured shapes with outstanding mechanical properties5-11, and are circularly integrated into the environment. Here we demonstrate a three-dimensional (3D) printing approach to generate recyclable lightweight structures with hierarchical architectures, complex geometries and unprecedented stiffness and toughness. Their features arise from the self-assembly of liquid-crystal polymer molecules into highly oriented domains during extrusion of the molten feedstock material. By orienting the molecular domains with the print path, we are able to reinforce the polymer structure according to the expected mechanical stresses, leading to stiffness, strength and toughness that outperform state-of-the-art 3D-printed polymers by an order of magnitude and are comparable with the highest-performance lightweight composites1,12. The ability to combine the top-down shaping freedom of 3D printing with bottom-up molecular control over polymer orientation opens up the possibility to freely design and realize structures without the typical restrictions of current manufacturing processes.

3D Bioprinting of Diatom-Laden Living Materials for Water Quality Assessment.

Diatoms have long been used as living biological indicators for the assessment of water quality in lakes and rivers worldwide. While this approach benefits from the great diversity of these unicellular algae, established protocols are time-consuming and require specialized equipment. Here, this work 3D prints diatom-laden hydrogels that can be used as a simple multiplex bio-indicator for water assessment. The hydrogel-based living materials are created with the help of a desktop extrusion-based printer using a suspension of diatoms, cellulose nanocrystals (CNC) and alginate as bio-ink constituents. Rheology and mechanical tests are employed to establish optimum bio-ink formulations, whereas cell culture experiments are utilized to evaluate the proliferation of the entrapped diatoms in the presence of selected water contaminants. Bioprinting of diatom-laden hydrogels is shown to be an enticing approach to generate living materials that can serve as low-cost bio-indicators for water quality assessment.

3D Printed Scaffolds for Monolithic Aerogel Photocatalysts with Complex Geometries.

Monolithic aerogels composed of crystalline nanoparticles enable photocatalysis in three dimensions, but they suffer from low mechanical stability and it is difficult to produce them with complex geometries. Here, an approach to control the geometry of the photocatalysts to optimize their photocatalytic performance by introducing carefully designed 3D printed polymeric scaffolds into the aerogel monoliths is reported. This allows to systematically study and improve fundamental parameters in gas phase photocatalysis, such as the gas flow through and the ultraviolet light penetration into the aerogel and to customize its geometric shape to a continuous gas flow reactor. Using photocatalytic methanol reforming as a model reaction, it is shown that the optimization of these parameters leads to an increase of the hydrogen production rate by a factor of three from 400 to 1200 µmol g-1 h-1 . The rigid scaffolds also enhance the mechanical stability of the aerogels, lowering the number of rejects during synthesis and facilitating handling during operation. The combination of nanoparticle-based aerogels with 3D printed polymeric scaffolds opens up new opportunities to tailor the geometry of the photocatalysts for the photocatalytic reaction and for the reactor to maximize overall performance without necessarily changing the material composition.

Three-dimensional printing of multicomponent glasses using phase-separating resins.

The digital fabrication of oxide glasses by three-dimensional (3D) printing represents a major paradigm shift in the way glasses are designed and manufactured, opening opportunities to explore functionalities inaccessible by current technologies. The few enticing examples of 3D printed glasses are limited in their chemical compositions and suffer from the low resolution achievable with particle-based or molten glass technologies. Here, we report a digital light-processing 3D printing platform that exploits the photopolymerization-induced phase separation of hybrid resins to create glass parts with complex shapes, high spatial resolutions and multi-oxide chemical compositions. Analogously to conventional porous glass fabrication methods, we exploit phase separation phenomena to fabricate complex glass parts displaying light-controlled multiscale porosity and dense multicomponent transparent glasses with arbitrary geometry using a desktop printer. Because most functional properties of glasses emerge from their transparency and multicomponent nature, this 3D printing platform may be useful for distinct technologies, sciences and arts.

Magnetic propulsion of colloidal microrollers controlled by electrically modulated friction.

Precise control over the motion of magnetically responsive particles in fluidic chambers is important for probing and manipulating tasks in prospective microrobotic and bio-analytical platforms. We have previously exploited such colloids as shuttles for the microscale manipulation of objects. Here, we study the rolling motion of magnetically driven Janus colloids on solid substrates under the influence of an orthogonal external electric field. Electrically induced attractive interactions were used to tune the load on the Janus colloid and thereby the friction with the underlying substrate, leading to control over the forward velocity of the particle. Our experimental data suggest that the frictional coupling required to achieve translation, transitions from a hydrodynamic regime to one of mixed contact coupling with increasing load force. Based on this insight, we show that our colloidal microrobots can probe the local friction coefficient of various solid surfaces, which makes them potentially useful as tribological microsensors. Lastly, we precisely manipulate porous cargos using our colloidal rollers, a feat that holds promise for bio-analytical applications.

Quantifying the role of mineral bridges on the fracture resistance of nacre-like composites.

The nacreous layer of mollusk shells holds design concepts that can effectively enhance the fracture resistance of lightweight brittle materials. Mineral bridges are known to increase the fracture resistance of nacre-inspired materials, but their role is difficult to quantify due to the lack of experimental systems where only this parameter is controllably varied. In this study, we fabricate tunable nacre-like composites that are used as a model to experimentally quantify the influence of the density of mineral bridges alone on the fracture properties of nacre-like architectures. The composites exhibit a brick-and-mortar architecture comprising highly aligned alumina platelets that are interconnected by titania mineral bridges and infiltrated by an epoxy organic phase. By combining experimental mechanical data with image analysis of such composite microstructures, an analytical model is put forward based on a simple balance of forces acting on an individual bridged platelet. Based on this model, we predict the flexural strength of the nacre-like composite to scale linearly with the density of mineral bridges, as long as the mineral interconnectivity is low enough to keep fracture in a platelet pullout mode. Increasing the mineral interconnectivity beyond this limit leads to platelet fracture and catastrophic failure of the composite. This structure-property correlation provides powerful quantitative guidelines for the design of lightweight brittle materials with enhanced fracture resistance. We illustrate this potential by fabricating nacre-like bulk composites with unparalleled flexural strength combined with noncatastrophic failure.

Wetting controls of droplet formation in step emulsification.

The formation of droplets is ubiquitous in many natural and industrial processes and has reached an unprecedented level of control with the emergence of milli- and microfluidics. Although important insight into the mechanisms of droplet formation has been gained over the past decades, a sound understanding of the physics underlying this phenomenon and the effect of the fluid's flow and wetting properties on the droplet size and production rate is still missing, especially for the widely applied method of step emulsification. In this work, we elucidate the physical controls of microdroplet formation in step emulsification by using the wetting of fluidic channels as a tunable parameter to explore a broad set of emulsification conditions. With the help of high-speed measurements, we unequivocally show that the final droplet pinch-off is triggered by a Rayleigh-Plateau-type instability. The droplet size, however, is not determined by the Rayleigh-Plateau breakup, but by the initial wetting regime, where the fluid's contact angle plays a crucial role. We develop a physical theory for the wetting process, which closely describes our experimental measurements without invoking any free fit parameter. Our theory predicts the initiation of the Rayleigh-Plateau breakup and the transition from dripping to jetting as a function of the fluid's contact angle. Additionally, the theory solves the conundrum why there is a minimal contact angle of α = 2π/3 = 120° for which droplets can form.

Cellulose-Based Microparticles for Magnetically Controlled Optical Modulation and Sensing.

Responsive materials with birefringent optical properties have been exploited for the manipulation of light in several modern electronic devices. While electrical fields are often utilized to achieve optical modulation, magnetic stimuli may offer an enticing complementary approach for controlling and manipulating light remotely. Here, the synthesis and characterization of magnetically responsive birefringent microparticles with unusual magneto-optical properties are reported. These functional microparticles are prepared via a microfluidic emulsification process, in which water-based droplets are generated in a flow-focusing device and stretched into anisotropic shapes before conversion into particles via photopolymerization. Birefringence properties are achieved by aligning cellulose nanocrystals within the microparticles during droplet stretching, whereas magnetic responsiveness results from the addition of superparamagnetic nanoparticles to the initial droplet template. When suspended in a fluid, the microparticles can be controllably manipulated via an external magnetic field to result in unique magneto-optical coupling effects. Using a remotely actuated magnetic field coupled to a polarized optical microscope, these microparticles can be employed to convert magnetic into optical signals or to estimate the viscosity of the suspending fluid through magnetically driven microrheology.

Design of textured multi-layered structures via magnetically assisted slip casting.

Multi-layered composites in nature often show functional properties that are determined by the specific orientation of inorganic building blocks within each layer. The shell of bivalve molluscs and the exoskeleton of crustaceans constitute prominent examples. An effective approach to artificially produce textured microstructures inspired by such complex composites is magnetically assisted slip casting (MASC). MASC is a colloidal process in which anisotropic particles are magnetically oriented at arbitrarily defined angles and collected at the surface of a porous mould to grow the material in an additive manner. Whereas a number of proof-of-concept studies have established the potential of the technique, the full design space available for MASC-fabricated structures, and the limits of the approach, have so far not been explored systematically. To fill this gap, we have studied both theoretically and experimentally the various torques that act on the particles at the different stages of the assembly process. We define the boundary conditions of the MASC process for magnetically responsive alumina platelets suspended in a low-viscosity aqueous suspension, considering the composition of the colloidal suspension and the dynamics of the particle alignment process under a rotating magnetic field. These findings lead to design guidelines for the fabrication of bio-inspired composites with customized multi-scale structures for a broad range of applications.

Periodically microstructured composite films made by electric- and magnetic-directed colloidal assembly.

Living organisms often combine soft and hard anisotropic building blocks to fabricate composite materials with complex microstructures and outstanding mechanical properties. An optimum design and assembly of the anisotropic components reinforces the material in specific directions and sites to best accommodate multidirectional external loads. Here, we fabricate composite films with periodic modulation of the soft-hard microstructure by simultaneously using electric and magnetic fields. We exploit forefront directed-assembly approaches to realize highly demanded material microstructural designs and showcase a unique example of how one can bridge colloidal sciences and composite technology to fabricate next-generation advanced structural materials. In the proof-of-concept experiments, electric fields are used to dictate the position of the anisotropic particles through dielectrophoresis, whereas a rotating magnetic field is used to control the orientation of the particles. By using such unprecedented control over the colloidal assembly process, we managed to fabricate ordered composite microstructures with up to 2.3-fold enhancement in wear resistance and unusual site-specific hardness that can be locally modulated by a factor of up to 2.5.

Addendum: Magnetically assisted slip casting of bioinspired heterogeneous composites.

This corrects the article DOI: 10.1038/nmat4419.

Emulsions Stabilized by Chitosan-Modified Silica Nanoparticles: pH Control of Structure-Property Relations.

In food-grade emulsions, particles with an appropriate surface modification can be used to replace surfactants and potentially enhance the stability of emulsions. During the life cycle of products based on such emulsions, they can be exposed to a broad range of pH conditions and hence it is crucial to understand how pH changes affect stability of emulsions stabilized by particles. Here, we report on a comprehensive study of the stability, microstructure, and macroscopic behavior of pH-controlled oil-in-water emulsions containing silica nanoparticles modified with chitosan, a food-grade polycation. We found that the modified colloidal particles used as stabilizers behave differently depending on the pH, resulting in unique emulsion structures at multiple length scales. Our findings are rationalized in terms of the different emulsion stabilization mechanisms involved, which are determined by the pH-dependent charges and interactions between the colloidal building blocks of the system. At pH 4, the silica particles are partially hydrophobized through chitosan modification, favoring their adsorption at the oil-water interface and the formation of Pickering emulsions. At pH 5.5, the particles become attractive and the emulsion is stabilized by a network of agglomerated particles formed between the droplets. Finally, chitosan aggregates form at pH 9 and these act as the emulsion stabilizers under alkaline conditions. These insights have important implications for the processing and use of particle-stabilized emulsions. On one hand, changes in pH can lead to undesired macroscopic phase separation or coalescence of oil droplets. On the other hand, the pH effect on emulsion behavior can be harnessed in industrial processing, either to tune their flow response by altering the pH between processing stages or to produce pH-responsive emulsions that enhance the functionality of the emulsified end products.

Strong Dual-Compartment Microcapsules Loaded with High Cargo Contents.

Compartmentalized microcapsules are useful for the release of multiple cargos in medicine, agriculture, and advanced responsive materials. Although several encapsulation strategies that involve more than one cargo have been proposed, dual- or multicompartment capsules with high cargo loadings and sufficient mechanical stability are rarely reported. Here, we propose a single-step emulsification route for the preparation of strong dual-compartment capsules that can host the main cargo in their core in combination with another liquid cargo stored within their thick shell. Capsules are produced through the polymerization of the middle oil phase of water-oil-water double emulsions made by microfluidics. Compartmentalization results from the phase separation of monomers within the middle phase of the double emulsion. We investigate the effect of such phase separation process on the microstructure and mechanical properties of the capsules and eventually illustrate the potential of this approach by creating thermosensitive capsules with programmable bursting temperature. The large variety of possible mixtures of monomers and cargos that can be added in the oil and aqueous phases of the double emulsion templates makes this encapsulation approach a promising route for the fabrication of robust microcapsules for on-demand release of multiple cargos.

Active cargo transport with Janus colloidal shuttles using electric and magnetic fields.

Active colloids show non-equilibrium behavior that departs from classical Brownian motion, thus providing a platform for novel fundamental phenomena and for enticing possible applications ranging from water treatment to medicine and microrobotics. Although the physics, motion mechanisms and guidance have been extensively investigated, active colloids are rarely exploited to simultaneously guide and transport micron-sized objects in a controllable and reversible manner. Here, we use autonomous active Janus particles as colloidal shuttles to controllably transport cargo at the microscale using external electric and magnetic fields. The active motion arises from the metallodielectric characteristics of the Janus particles, which allows them to also trap, transport and release cargo particles through dielectrophoretic interactions induced by an AC electric field. The ferromagnetic nature of the nickel layer that forms the metallic hemisphere of the Janus colloids provides an additional mechanism to direct the motion of the shuttle using an external magnetic field. With this highly programmable colloidal system, we are able to harness active colloid motion and use it to transport cargo particles to specific destinations through a pre-defined route. A simple analytical model is derived to successfully describe the motion of the shuttle-cargo assembly in response to the applied electrical field. The high level of control on cargo pick-up, transport and release leads to a powerful delivery tool, which could eventually be used in microactuators, microfluidics or for controlled delivery within organ-on-a-chip devices.

Early Dynamics and Stabilization Mechanisms of Oil-in-Water Emulsions Containing Colloidal Particles Modified with Short Amphiphiles: A Numerical Study.

Emulsions stabilized by mixtures of particles and amphiphilic molecules are relevant for a wide range of applications, but their dynamics and stabilization mechanisms on the colloidal level are poorly understood. Given the challenges to experimentally probe the early dynamics and mechanisms of droplet stabilization, Brownian dynamics simulations are developed here to study the behavior of oil-in-water emulsions stabilized by colloidal particles modified with short amphiphiles. Simulation parameters are based on an experimental system that consists of emulsions obtained with octane as the oil phase and a suspension of alumina colloidal particles modified with short carboxylic acids as the continuous aqueous medium. The numerical results show that attractive forces between the colloidal particles favor the formation of closely packed clusters on the droplet surface or of a percolating network of particles throughout the continuous phase, depending on the amphiphile concentration. Simulations also reveal the importance of a strong adsorption of particles at the liquid interface to prevent their depletion from the droplet surface when another droplet approaches. Strongly adsorbed particles remain immobile on the droplet surface, generating an effective steric barrier against droplet coalescence. These findings provide new insights into the early dynamics and mechanisms of stabilization of emulsions using particles and amphiphilic molecules.

Functional Microcapsules with Hybrid Shells Made via Sol-Gel Reaction within Double Emulsions.

Microcapsules with organic-inorganic hybrid shells can be used as functionally responsive delivery systems that are attractive for a broad range of applications. Hybrid-shell microcapsules have often been synthesized by the assembly of solid inorganic nanoparticles and polymers. Efforts to extend this approach to microfluidic emulsification have been hampered by problems with clogging and flow instabilities when utilizing dispersions of solid particles. In this work, hybrid shell microcapsules are synthesized through the reaction of liquid precursors, eliminating the use of solid dispersions. Our microfluidic water-oil-water emulsification technique also enables the preparation of hybrid-shell microcapsules with thicker and more robust shells compared to alternative techniques. By utilizing bridged-silane precursors to form the hybrid material, we demonstrate hybrid-shell microcapsules with independently tunable functional and mechanical/barrier properties. This independent tuning of physical and functional properties allows for the production of functional organic-inorganic hybrid shell microcapsules that can be tailored to meet the demands of a wide range of applications.

Strong Microcapsules with Permeable Porous Shells Made through Phase Separation in Double Emulsions.

Microcapsules for controlled chemical release and uptake are important in many industrial applications but are often difficult to produce with the desired combination of high mechanical strength and high shell permeability. Using water-oil-water double emulsions made in microfluidic devices as templates, we developed a processing route to obtain mechanically robust microcapsules exhibiting a porous shell structure with controlled permeability. The porous shell consists of a network of interconnected polymer particles that are formed upon phase separation within the oil phase of the double emulsion. Porosity is generated by an inert diluent incorporated in the oil phase. The use of undecanol and butanol as inert diluents allows for the preparation of microcapsules covering a wide range of shell-porosity and force-at-break values. We found that the amount and chemical nature of the diluent influence the shell porous structure by changing the mechanism of phase separation that occurs during polymerization. In a proof-of-concept experiment, we demonstrate that the mechanically robust microcapsules prepared through this simple approach can be utilized for the on-demand release of small molecules using a pH change as exemplary chemical trigger.