Nanoscale building blocks of many materials exhibit extraordinary mechanical properties due to their defect-free molecular structure. Translation of these high mechanical properties to macroscopic materials represents a difficult materials engineering challenge due to the necessity to organize these building blocks into multiscale patterns and mitigate defects emerging at larger scales. Cellulose nanofibrils (CNFs), the most abundant structural element in living systems, has impressively high strength and stiffness, but natural or artificial cellulose composites are 3–15 times weaker than the CNFs. Here, we report the flow-assisted organization of CNFs into macroscale fibers with nearly perfect unidirectional alignment. Efficient stress transfer from macroscale to individual CNF due to cross-linking and high degree of order enables their Young’s modulus to reach up to 86 GPa and a tensile strength of 1.57 GPa, exceeding the mechanical properties of known natural or synthetic biopolymeric materials. The specific strength of our CNF fibers engineered at multiscale also exceeds that of metals, alloys, and glass fibers, enhancing the potential of sustainable lightweight high-performance materials with multiscale self-organization.

Nature’s design of functional materials relies on smart combinations of simple components to achieve desired properties. Silk and cellulose are two clever examples from nature–spider silk being tough due to high extensibility, whereas cellulose possesses unparalleled strength and stiffness among natural materials. Unfortunately, silk proteins cannot be obtained in large quantities from spiders, and recombinant production processes are so far rather expensive. We have therefore combined small amounts of functionalized recombinant spider silk proteins with the most abundant structural component on Earth (cellulose nanofibrils (CNFs)) to fabricate isotropic as well as anisotropic hierarchical structures. Our approach for the fabrication of bio-based anisotropic fibers results in previously unreached but highly desirable mechanical performance with a stiffness of ∼55 GPa, strength at break of ∼1015 MPa, and toughness of ∼55 MJ m^–3. We also show that addition of small amounts of silk fusion proteins to CNF results in materials with advanced biofunctionalities, which cannot be anticipated for the wood-based CNF alone. These findings suggest that bio-based materials provide abundant opportunities to design composites with high strength and functionalities and bring down our dependence on fossil-based resources.

Mechanistic behavior and flow properties of cellulose nanofibers (CNFs) in aqueous systems can be described by the crowding factor and the concept of contact points, which are functions of the aspect ratio and concentration of CNF in the suspension. In this study, CNFs with a range of aspect ratio and surface charge density (380–1360 μmol/g) were used to demonstrate this methodology. It was shown that the critical networking point of the CNF suspension, determined by rheological measurements, was consistent with the gel crowding factor, which was 16. Correlated to the crowding factor, both viscosity and modulus of the systems were found to decrease by increasing the charge density of CNF, which also affected the flocculation behavior. Interestingly, an anomalous rheological behavior was observed near the overlap concentration (0.05 wt %) of CNF, at which the crowding factor was below the gel crowding factor, and the storage modulus (G′) decreased dramatically at a given frequency threshold. This behavior is discussed in relation to the breakup of the entangled flocs and network in the suspension. The analysis of the mechanistic behavior of CNF aqueous suspensions by the crowding factor provides useful insight for fabricating high-performance nanocellulose-based materials.

Significance: Protein nanofibrils formed by self-assembly have emerged as a promising foundation for the design of bio-based materials with enhanced mechanical properties or new functionality. To make use of the extraordinary properties of these structures in materials design, improved understanding of the assembly of the nanofibrils into macroscale materials is crucial. Here we demonstrate that micrometer-sized protein fibers can be created from protein nanofibrils using a simple microfluidics setup. The assembly mechanism of these fibers is elucidated using high-resolution small-angle X-ray studies in combination with rheology measurements of the corresponding hydrogels. The results reveal essential parameters associated with the fiber formation and provide insights about the assembly processes of hierarchical protein materials.

Microfluidics has proven to be an efficient tool for making fine and calibrated emulsion droplets. The parallelization of drop makers is required for producing large amounts. Here, we investigate the generation of emulsion drops along a series of shallow microchannels emerging in a deep one, in other words the step-emulsification process. The dynamics of a single drop maker is first characterized as a function of interfacial tension and viscosities of both phases. The characteristic time scale of drop formation, namely, the necking time that finally sets drop size, is shown to be principally governed by the outer phase viscosity to interfacial tension ratio with a minor correction linked to the viscosity ratio. The step emulsification process experiences a transition of fragmentation regime where both the necking time and drop size suddenly raise. This transition, that corresponds to a critical period of drop formation and thus defines a maximum production rate of small droplets, is observed to be ruled by the viscosity ratio of the two phases. When drops are produced along an array of microchannels with a cross flow of the continuous phase, a configuration comparable to a one-dimensional membrane having rectangular pores, a drop boundary layer develops along the drop generators. In the small drop regime, the local dynamics of drop formation is shown to be independent on the emulsion cross flow. Moreover, we note that the development of the drop boundary layer is even beneficial to homogenize drop size along the production line. On the other hand, in the large drop regime, drop collision can trigger fragmentation and thus lead to size polydispersity.

Many nanoscale biopolymer building blocks with defect-free molecular structure and exceptional mechanical properties have the potential to surpass the performance of existing fossil-based materials with respect to barrier properties, load-bearing substrates for advanced functionalities, as well as light-weight construction. Comprehension and control of performance variations of macroscopic biopolymer materials caused by humidity-driven structural changes at the nanoscale are imperative and challenging. A long-lasting challenge is the interaction with water molecules causing reversible changes in the intrinsic molecular structures that adversely affects the macroscale performance. Using in situ advanced X-ray and neutron scattering techniques, we reveal the structural rearrangements at the nanoscale in ultrathin nanocellulose films with humidity variations. These reversible rearrangements are then correlated with wettability that can be tuned. The results and methodology have general implications not only on the performance of cellulose-based materials but also for hierarchical materials fabricated with other organic and inorganic moisture-sensitive building blocks.