Abstract
Complex-shaped microparticles can enhance applications in drug delivery, tissue engineering, and structural materials, although techniques to fabricate these particles remain limited. A microfluidics-based process called optofluidic fabrication that utilizes inertial flows and ultraviolet polymerization has shown great potential for creating highly 3D-shaped particles in a high-throughput manner, but the particle dimensions are mainly at the millimeter scale. Here, a next generation optofluidic fabrication process is presented that utilizes on-the-fly fabricated multiscale fluidic channels producing customized sub-100 µm 3D-shaped microparticles. This flexible design scheme offers a user-friendly platform for rapid prototyping of new 3D particle shapes, providing greater potential for creating impactful engineered microparticles.