Tuning three-dimensional (3D) shapes of polymeric microparticles by geometry-driven control of mold swelling and capillarity in micromolds.

We report a simple method for producing polymeric microparticles with controlled three-dimensional (3D) shapes from two-dimensional (2D) micromolds via mold geometry-mediated tunable mold swelling and capillarity. Specifically, the photocurable solution confined in the mold with diverse geometries is spatially deformed by the addition of the wetting fluid, which triggers the mold swelling and capillarity; this allows the production of highly uniform microparticles with complex shape via photopolymerization. The results show that the swelling-induced mold deflection is varied depending on the mold geometry with different side lengths, allowing a tunable deformation of the photocurable solution and forming non-spherical particles with a convex top. The capillarity of the wetting fluid is also determined by the mold geometry with different corner angles, leading to the directional movement of the photocurable solution via Laplace pressure-driven flow and facilitating the production of spherical particles with or without shape imprinting. Furthermore, we demonstrate a capability to further enhance the mold swelling by varying mold composition, expanding their controllability in 3D shape, and enabling simultaneous production of spherical and non-spherical particles using a single mold.