A curable sheath fluid and a core fluid are simultaneously introduced from a hydrodynamic nozzle to form a co-flowing extrusion, depositing at least a portion of the co-flowing extrusion on a material bed, and causing relative motion between the hydrodynamic nozzle and the material bed to form an extruded shape. The method comprises curing part or all of the external curable fluid. The method may introduce co-flowing extrusion to pressure to remove the internal core fluid from the external curable fluid, and may receive the core fluid into the fluid drain system. The extruded shapes may form a tube or plurality of tubes in a bundle or porous substrate. The ability to form concentric tubes and complex shapes provides a means forming high strength materials controlled release materials, and self-repair materials.

The present disclosure is directed to tailoring the structure of freeform nanotube macrostructures through extrusion-based additive manufacturing for fabrication of planar and three-dimensional features and objects. Ink containing nanomaterials can be extruded into a fluid to precipitate into a fiber that can be used to form solid structures. The fluid can include a coagulant that promotes rapid solidification in the precipitation of fibers. The fluid can be disposed into a bath that is in fluid communication with the extruded ink. Systems and devices for executing such processes, are also provided.

A co-extrusion device includes at least one first inlet port to receive a first material, at least one second inlet port to receive a second material, a first combining channel arranged to receive the first material and the second material and combine the first and second materials into a first combined flow flowing in a first direction, a splitter channel arranged to receive the first combined flow and to split the first combined flow into at least two split flows in a second direction at least partially orthogonal to the first direction, wherein each split flow consists of the first and second materials, a second combining channel arranged to receive the split flows and combine the split flows into a second combined flow in the first direction, and at least one exit orifice arranged to allow the materials to exit the device as a single flow.

A method for depositing a structure comprising interdigitated materials includes merging flows of at least two materials in a first direction into a first combined flow, dividing the first combined flow in a second direction to produce at least two separate flows, wherein the second direction is perpendicular to the first direction, and merging the two separate flows into a second combined flow.

This invention is directed to a microstructured filament that can be used to make fibers having an extruded filament having pre-cooled microfeatures in a radial spiral arrangement about a bore though the filament wherein the microfeature has a width in the range of 25 m to 40 m and height in the range of 90 m to 100 m; and, the filament having a post-cooled state having post-cooled microfeatures having physical dimensions smaller than that of the pre-cooled microfeatures. The filament can include microfeatures having a width in the range of 400 nm to 4 m and height in the range of 400 nm to 4 m. The filament and fiber can include physical characteristics selected from the group consisting of: hydrophobicity, self-cleaning, increased hydro-dynamic drag coefficients, decreased or increased aerodynamic drag coefficients, increased friction, reduced friction, optical effects, increased adhesion, decreased adhesion, oleophobicity, tactile effects, anti-blocking and any combination of these.