Process of making three-dimensional microstructures using vaporization of a sacrificial component.

Vascular structures in natural systems are able to provide high mass transport through high surface areas and optimized structure. Few synthetic material fabrication techniques are able to mimic the complexity of these structures while maintaining scalability. The Vaporization of a Sacrificial Component (VaSC) process is able to do so. This process uses sacrificial fibers as a template to form hollow, cylindrical microchannels embedded within a matrix. Tin (II) oxalate (SnOx) is embedded within poly(lactic) acid (PLA) fibers which facilitates the use of this process. The SnOx catalyzes the depolymerization of the PLA fibers at lower temperatures. The lactic acid monomers are gaseous at these temperatures and can be removed from the embedded matrix at temperatures that do not damage the matrix. Here we show a method for aligning these fibers using micromachined plates and a tensioning device to create complex patterns of three-dimensionally arrayed microchannels. The process allows the exploration of virtually any arrangement of fiber topologies and structures.

A three-dimensional microvascular gas exchange unit for carbon dioxide capture.

For the capture of CO(2) from mixed gas streams, materials for increased gas exchange are necessary. Efficient gas exchange systems already exist in the form of vascularized lung-tissue. Herein we report a fabrication technique for the synthesis of three-dimensional microvascular gas exchange units capable of removing CO(2) from flowing gas created using the recently reported Vaporization of a Sacrificial Component (VaSC) technique. We demonstrate the spatiotemporal pattern of CO(2) reactivity in the microvascular gas exchange unit using colorimetric, pH sensitive dyes. Control over three-dimensional placement of channels is shown to increase capture efficiencies. A computational finite element model validates and explains the experimental observations.