Precision Fiber Engineering via Microfluidic Spinning for Next-Generation Smart Wearable Textiles: A Review

Abstract

Microfluidic spinning technology is an exact fiber fabrication technique leveraging microfluidic control principles. Through precise regulation of the spinning solution's rheological properties, the microfluidic chip's channel architecture, and solidification mechanisms, this technique enables accurate control over the morphology, size, and composition of fibers. In recent years, it has demonstrated significant potential in the realm of smart wearable devices, promoting the development of flexible electronics, intelligent textiles, and human health monitoring. To this end, this review systematically summarizes the latest progress of microfluidic spinning technology, covering foundational aspects such as chip materials, channel architectures, solidification strategies, and fluidic principles. Particular emphasis was placed on the structural design, fabrication strategies, and resultant properties (e.g., electrical conductivity, mechanical flexibility, and multifunctional capabilities) of microfluidic-spun conductive composite fibers, which serve as critical components for smart textiles.Furthermore, the applications of these functional fibers within smart wearable textiles, particularly in sensing (e.g., strain, gas, temperature, multimodal), electrochemical energy storage, and intelligent thermal management, were analyzed. It included an analysis of integration strategies into fabrics and the development of an integrated wearable system that combined hardware and software components. In addition, this paper addresses current technological challenges and outlines future development trends, including process optimization, large-scale production, multifunctional integration, and self-powered sustainability. The continued evolution of microfluidic spinning technology will provide more efficient, flexible, and intelligent manufacturing solutions for next-generation smart wearable devices.