Printing microstructures in a polymer matrix using a ferrofluid droplet

We print complex curvilinear microstructures in an elastomer matrix using a ferrofluid droplet as the print head. A magnetic field moves the droplet along a prescribed path in liquid polydimethylsiloxane (PDMS). The droplet sheds magnetic nanoparticle (MNP) clusters in its wake, forming printed features. The PDMS is subsequently heated so that it crosslinks, which preserves the printed features in the elastomer matrix. The competition between magnetic and drag forces experienced by the ferrofluid droplet and its trailing MNPs highlight design criteria for successful printing, which are experimentally confirmed. The method promises new applications, such as flexible 3D circuitry.