The
type I collagen monomer is one of nature’s most exquisite
and prevalent structural tools. Its 300 nm triple-helical motifs assemble
into tough extracellular fibers that transition seamlessly across
tissue boundaries and exceed cell dimensions by up to 4 orders of
magnitude. In spite of extensive investigation, no existing model
satisfactorily explains how such continuous structures are generated
and grown precisely where they are needed (aligned in the path of
force) by discrete, microscale cells using materials with nanoscale
dimensions. We present a simple fiber drawing experiment, which demonstrates
that slightly concentrated type I collagen monomers can be “flow-crystallized”
to form highly oriented, continuous, hierarchical fibers at cell-achievable
strain rates (–1) and physiologically relevant
concentrations (∼50 μM). We also show that application
of tension following the drawing process maintains the structural
integrity of the fibers. While mechanical tension has been shown to
be a critical factor driving collagen fibril formation during tissue
morphogenesis in developing animals, the precise role of force in
the process of building tissue is not well understood. Our data directly
couple mechanical tension, specifically the extensional strain rate,
to collagen fibril assembly. We further derive a “growth equation”
which predicts that application of extensional strains, either globally
by developing muscles or locally by fibroblasts, can rapidly drive
the fusion of already formed short fibrils to produce long-range,
continuous fibers. The results provide a pathway to scalable connective
tissue manufacturing and support a mechano-biological model of collagen
fibril deposition and growth in vivo