Low-Voltage Continuous Electrospinning Patterning

Biofabrication methods for reconstructing extracellular matrix mimetics

In the human body, almost all cells interact with extracellular matrices (ECMs), which have tissue and organ-specific compositions and architectures. These ECMs not only function as cellular scaffolds, providing structural support, but also play a crucial role in dynamically regulating various cellular functions. This comprehensive review delves into the examination of biofabrication strategies used to develop bioactive materials that accurately mimic one or more biophysical and biochemical properties of ECMs. We discuss the potential integration of these ECM-mimics into a range of physiological and pathological in vitro models, enhancing our understanding of cellular behavior and tissue organization. Lastly, we propose future research directions for ECM-mimics in the context of tissue engineering and organ-on-a-chip applications, offering potential advancements in therapeutic approaches and improved patient outcomes.

Biointerface Fiber Technology from Electrospinning to Inflight Printing

Building two-dimensional (2D) and three-dimensional (3D) micro- and nanofibril structures with designable patterns and functionalities will offer exciting prospects for numerous applications spanning from permeable bioelectronics to tissue engineering scaffolds. This Spotlight on Applications highlights recent technological advances in fiber printing and patterning with functional materials for biointerfacing applications. We first introduce the current state of development of micro- and nanofibers with applications in biology and medical wearables. We then describe our contributions in developing a series of fiber printing techniques that enable the patterning of functional fiber architectures in three dimensions. These fiber printing techniques expand the material library and device designs, which underpin technological capabilities from enabling fundamental studies in cell migration to customizable and ecofriendly fabrication of sensors. Finally, we provide an outlook on the strategic pathways for developing the next-generation bioelectronics and "Fiber-of-Things" (FoT) using nano/micro-fibers as architectural building blocks.

2D and 3D Electrospinning of Nanofibrous Structures by Far-Field Jet Writing

Electrospinning offers remarkable versatility in producing superfine fibrous materials and is hence widely used in many applications such as tissue scaffolds, filters, electrolyte fuel cells, biosensors, battery electrodes, and separators. Nevertheless, it is a challenge to print pre-designed 2D/3D nanofibrous structures using electrospinning due to its inherent jet instability. Here, we report on a novel far-field jet writing technique for precisely controlling the polymer jet in nanofiber deposition, which was achieved through a combination of reducing the nozzle voltage, adjusting the electric field, and applying a set of passively focusing electrostatic lenses. By optimizing the applied voltage, the circular aperture of lenses, and the distance between the adjacent lenses, the best precision achieved using this technique was approximately 200 μm, similar to that of a conventional polymer-based 3D printer. This development makes it possible for printing 2D/3D nanofibrous structures by far-field jet writing for different applications with enhanced performance.

Electrohydrodynamic 3D Printing of Aqueous Solutions

Among the various electrohydrodynamic (EHD) processing techniques, electrowriting (EW) produces the most complex 3D structures. Aqueous solution EW similarly retains the potential for additive manufacturing well-resolved 3D structures, while providing new opportunities for processing biologically derived polymers and eschewing organic solvents. However, research on aqueous-based EHD processing is still limited. To summarize the field and advocate for increased use of aqueous bio-based materials, this review summarizes the most significant contributions of aqueous solution processing. Special emphasis has been placed on understanding the effects of different printing parameters, the prospects for 3D processing new materials, and future challenges.

Preparation and Use of Decellularized Extracellular Matrix for Tissue Engineering

The multidisciplinary fields of tissue engineering and regenerative medicine have the potential to revolutionize the practise of medicine through the abilities to repair, regenerate, or replace tissues and organs with functional engineered constructs. To this end, tissue engineering combines scaffolding materials with cells and biologically active molecules into constructs with the appropriate structures and properties for tissue/organ regeneration, where scaffolding materials and biomolecules are the keys to mimic the native extracellular matrix (ECM). For this, one emerging way is to decellularize the native ECM into the materials suitable for, directly or in combination with other materials, creating functional constructs. Over the past decade, decellularized ECM (or dECM) has greatly facilitated the advance of tissue engineering and regenerative medicine, while being challenged in many ways. This article reviews the recent development of dECM for tissue engineering and regenerative medicine, with a focus on the preparation of dECM along with its influence on cell culture, the modification of dECM for use as a scaffolding material, and the novel techniques and emerging trends in processing dECM into functional constructs. We highlight the success of dECM and constructs in the in vitro, in vivo, and clinical applications and further identify the key issues and challenges involved, along with a discussion of future research directions.

Self-Searching Writing of Human-Organ-Scale Three-Dimensional Topographic Scaffolds with Shape Memory by Silkworm-like Electrospun Autopilot Jet

Bioengineered scaffolds satisfying both the physiological and anatomical considerations could potentially repair partially damaged tissues to whole organs. Although three-dimensional (3D) printing has become a popular approach in making 3D topographic scaffolds, electrospinning stands out from all other techniques for fabricating extracellular matrix mimicking fibrous scaffolds. However, its complex charge-influenced jet-field interactions and the associated random motion were hardly overcome for almost a century, thus preventing it from being a viable technique for 3D topographic scaffold construction. Herein, we constructed, for the first time, geometrically challenging 3D fibrous scaffolds using biodegradable poly(ε-caprolactone), mimicking human-organ-scale face, female breast, nipple, and vascular graft, with exceptional shape memory and free-standing features by a novel field self-searching process of autopilot polymer jet, essentially resembling the silkworm-like cocoon spinning. With a simple electrospinning setup and innovative writing strategies supported by simulation, we successfully overcame the intricate jet-field interactions while preserving high-fidelity template topographies, via excellent target recognition, with pattern features ranging from 100's μm to 10's cm. A 3D cell culture study ensured the anatomical compatibility of the so-made 3D scaffolds. Our approach brings the century-old electrospinning to the new list of viable 3D scaffold constructing techniques, which goes beyond applications in tissue engineering.

Near-Field Electrospinning: Crucial Parameters, Challenges, and Applications

Near-field electrospinning (NFES) is a micro- or nanofiber production technology based on jetting molten polymer or polymer solution. Thanks to the programmable collector and nozzle movement, it can generate designed patterns in the presence of an electric field. Despite a few shortcomings of NFES, its high resolution, simplicity, precision, high throughput, reproducibility, and low costs have convinced researchers to employ it for various purposes. Furthermore, as the paradigm of fiber-based structures shifts from random textures toward delicate designs, NFES can bridge the gap between existing inefficient processes and aspired technologies for precise patterning. NFES facilitates the production of ultrafine nanofibers because it can be used to fabricate them in every laboratory. These robust fibers are convenient tools for small and additive manufacturing. As such, NFES is considered a potent additive fabrication technology that facilitates the production of complicated patterns as well. It is suggested that near-field electrospun fibers exhibit outstanding results in various applications, owing to their precise and controllable positioning. Meanwhile, the ongoing development of NFES has yet to reach its climax, making it attractive for further research. In this review, the basic principles of NFES, derivatives, limitations, and applications in nanomanufacturing, tissue engineering, microscale electronics, biosensors, and optics are presented.

Cancer cell migration on straight, wavy, loop and grid microfibre patterns

Cell migration plays an important role in physiological and pathological processes where the fibrillar morphology of extracellular matrices (ECM) could regulate the migration dynamics. To mimic the morphological characteristics of fibrillar matrix structures, low-voltage continuous electrospinning was adapted to construct straight, wavy, looped and gridded fibre patterns made of polystyrene (of fibre diameter ca. 3 μm). Cells were free to explore their different shapes in response to the directly-adhered fibre, as well as to the neighbouring patterns. For all the patterns studied, analysing cellular migration dynamics of MDA-MB-231 (a highly migratory breast cancer cell line) demonstrated two interesting findings: first, although cells dynamically adjust their shapes and migration trajectories in response to different fibrillar environments, their average step speed is minimally affected by the fibre global pattern; secondly, a switch in behaviour was observed when the pattern features approach the upper limit of the cell body's minor axis, reflecting that cells' ability to divert from an existing fibre track is limited by the size along the cell body's minor axis. It is therefore concluded that the upper limit of cell body's minor axis might act as a guide for the design of microfibre patterns for different purposes of cell migration.

Renal Biology Driven Macro- and Microscale Design Strategies for Creating an Artificial Proximal Tubule Using Fiber-Based Technologies

Chronic kidney disease affects one in six people worldwide. Due to the scarcity of donor kidneys and the complications associated with hemodialysis (HD), a cell-based bioartificial kidney (BAK) device is desired. One of the shortcomings of HD is the lack of active transport of solutes that would normally be performed by membrane transporters in kidney epithelial cells. Specifically, proximal tubule (PT) epithelial cells play a major role in the active transport of metabolic waste products. Therefore, a BAK containing an artificial PT to actively transport solutes between the blood and the filtrate could provide major therapeutic advances. Creating such an artificial PT requires a biocompatible tubular structure which supports the adhesion and function of PT-specific epithelial cells. Ideally, this scaffold should structurally replicate the natural PT basement membrane which consists mainly of collagen fibers. Fiber-based technologies such as electrospinning are therefore especially promising for PT scaffold manufacturing. This review discusses the use of electrospinning technologies to generate an artificial PT scaffold for ex vivo/in vivo cellularization. We offer a comparison of currently available electrospinning technologies and outline the desired scaffold properties required to serve as a PT scaffold. Discussed also are the potential technologies that may converge in the future, enabling the effective and biomimetic incorporation of synthetic PTs in to BAK devices and beyond.

From Protein Building Blocks to Functional Materials

Proteins are the fundamental building blocks for high-performance materials in nature. Such materials fulfill structural roles, as in the case of silk and collagen, and can generate active structures including the cytoskeleton. Attention is increasingly turning to this versatile class of molecules for the synthesis of next-generation green functional materials for a range of applications. Protein nanofibrils are a fundamental supramolecular unit from which many macroscopic protein materials are formed. In this Review, we focus on the multiscale assembly of such protein nanofibrils formed from naturally occurring proteins into new supramolecular architectures and discuss how they can form the basis of material systems ranging from bulk gels, films, fibers, micro/nanogels, condensates, and active materials. We review current and emerging approaches to process and assemble these building blocks in a manner which is different to their natural evolutionarily selected role but allows the generation of tailored functionality, with a focus on microfluidic approaches. We finally discuss opportunities and challenges for this class of materials, including applications that can be involved in this material system which consists of fully natural, biocompatible, and biodegradable feedstocks yet has the potential to generate materials with performance and versatility rivalling that of the best synthetic polymers.

Near-Field Electrospinning and Melt Electrowriting of Biomedical Polymers-Progress and Limitations

Near-field electrospinning (NFES) and melt electrowriting (MEW) are the process of extruding a fiber due to the force exerted by an electric field and collecting the fiber before bending instabilities occur. When paired with precise relative motion between the polymer source and the collector, a fiber can be directly written as dictated by preprogrammed geometry. As a result, this precise fiber control results in another dimension of scaffold tailorability for biomedical applications. In this review, biomedically relevant polymers that to date have manufactured fibers by NFES/MEW are explored and the present limitations in direct fiber writing of standardization in published setup details, fiber write throughput, and increased ease in the creation of complex scaffold geometries are discussed.

Guided Assembly and Patterning of Intrinsically Fluorescent Amyloid Fibers with Long-Range Order

Fibrillar amyloids exhibit a fascinating range of mechanical, optical, and electronic properties originating from their characteristic β-sheet-rich structure. Harnessing these functionalities in practical applications has so far been hampered by a limited ability to control the amyloid self-assembly process at the macroscopic scale. Here, we use core-shell electrospinning with microconfinement to assemble amyloid-hybrid fibers, consisting of densely aggregated fibrillar amyloids stabilized by a polymer shell. Up to centimeter-long hybrid fibers with micrometer diameter can be arranged into aligned and ordered arrays and deposited onto substrates or produced as free-standing networks. Properties that are characteristic of amyloids, including their high elastic moduli and intrinsic fluorescence signature, are retained in the hybrid fiber cores, and we show that they fully persist through the macroscopic fiber patterns. Our findings suggest that microlevel confinement is key for the guided assembly of amyloids from monomeric proteins.

Hydrogel-Based Bioinks for Cell Electrowriting of Well-Organized Living Structures with Micrometer-Scale Resolution

Bioprinting has become an important tool for fabricating regenerative implants and in vitro cell culture platforms. However, until today, extrusion-based bioprinting processes are limited to resolutions of hundreds of micrometers, which hamper the reproduction of intrinsic functions and morphologies of living tissues. This study describes novel hydrogel-based bioinks for cell electrowriting (CEW) of well-organized cell-laden fiber structures with diameters ranging from 5 to 40 μm. Two novel photoresponsive hydrogel bioinks, that is, based on gelatin and silk fibroin, which display distinctly different gelation chemistries, are introduced. The rapid photomediated cross-linking mechanisms, electrical conductivity, and viscosity of these two engineered bioinks allow the fabrication of 3D ordered fiber constructs with small pores (down to 100 μm) with different geometries (e.g., squares, hexagons, and curved patterns) of relevant thicknesses (up to 200 μm). Importantly, the biocompatibility of the gelatin- and silk fibroin-based bioinks enables the fabrication of cell-laden constructs, while maintaining high cell viability post printing. Taken together, CEW and the two hydrogel bioinks open up fascinating opportunities to manufacture microstructured constructs for applications in regenerative medicine and in vitro models that can better resemble cellular microenvironments.

Low-Voltage Continuous Electrospinning: A Versatile Protocol for Patterning Nano- and Micro-Scaled Fibers for Cell Interface

Nano- and micro-scaled fibers have been incorporated in a number of applications in biofabrication and tissue cultures, providing a cell interfacing structure with extracellular matrix-mimicking topography and adhesion sites, and further supporting localized drug release. Here, we describe the low-voltage electrospinning patterning (LEP) protocol, which allows direct and continuous patterning of sub-micron fibers in a controlled fashion. The processable polymers range from protein (e.g., gelatin) to thermoplastic (e.g., polystyrene) polymers, with flexible selections of collecting substrates. The operation voltage for fiber fabrication can be as low as 50 V, which brings the benefits of reducing costs and mild-processing.

Microtip focused electrohydrodynamic jet printing with nanoscale resolution

Electrohydrodynamic jet (E-Jet) printing is a promising manufacturing technique for micro-/nano-patterned structures with high resolution, high efficiency and high material compatibility. However, further improvement of the necking ratio of the E-Jet is still limited by the focusing principle. Moreover, ink viscosity is limited to values well below 90 mPa s owing to the high probability of nozzle blockage. Here, we propose a microtip focused electrohydrodynamic jet (MFEJ) printing to overcome these limitations. This technique uses a solid microtip with a radius of curvature (ROC) of several micrometers rather than a hollow nozzle, which is very simple and highly efficient to prepare and can effectively avoid nozzle clogging problems even with high-viscosity printing ink. High-resolution patterns in diverse geometries were printed using different inks with a wide range of viscosities (8.4-3500 mPa s). Nanodroplets with an average diameter of 73 nm were achieved. Moreover, nanofibers with a diameter of 30 nm were obtained using a 4 μm ROC microtip and the necking ratio was as high as 266 : 1. To the best of our knowledge, this is the smallest droplet or fiber diameter directly obtained via E-Jet printing to date without further physical or chemical processing. This MFEJ printing technique can improve printing resolution at the nanoscale, significantly enlarge the material applicability and effectively avoid nozzle clogging for the fabrication of nanodevices.

Composite Membranes with Nanofibrous Cross-Hatched Supports for Reverse Osmosis Desalination

A novel membrane structure composed of cross-hatched electrospun nanofibers is developed. We illustrate that this novel structure allows for much higher water permeability when used as a support for reverse osmosis thin-film composite membranes. Reinforcement and lamination of the aligned nanofibers generates mechanically robust structures that retain very high porosity and low tortuosity when applied to high pressure desalination operations. The cross-hatched nanofiber layers support the polyamide active layer firmly and reduce resistance to water flow due to the high porosity, low tortuosity, high mechanical strength, and minimal thickness of the structures. The nanofiber composite membrane gives a water flux significantly greater than when a traditional support layer is used, at 99 ± 5 m^-2 h^-1 with NaCl rejection of 98.7% at 15.5 bar.

Tailoring the Diameters of Electro-Mechanically Spun Fibers by Controlling Their Deborah Numbers

Polymer solutions with different concentrations of SU-8 2002/poly(ethylene) glycol/tetrabutyl ammonium tetrafluoroborate (SU-8/PEO/TBATFB) were electrospun in a low-voltage near-field electrospinning platform (LVNFES) at different velocities. Their diameters were related to the concentration contents as well as to their Deborah (De) numbers, which describes the elasticity of the polymer solution under determined operating conditions. We found a direct correlation between the concentration of PEO/TBATFB, the De and the diameter of the fibers. Fibers with diameters as thin as 465 nm can be achieved for De ≈ 1.

Fabrication of patterned graphitized carbon wires using low voltage near-field electrospinning, pyrolysis, electrodeposition, and chemical vapor deposition

We herein report a high-resolution nanopatterning method using low voltage electromechanical spinning with a rotating collector to obtain aligned graphitized micro and nanowires for carbon nanomanufacturing. A small wire diameter and a small inter-wire spacing were obtained by controlling the electric field, the spinneret-to-collector distance, the pyrolysis parameters, the linear speed of the spinneret, the rotational speed of the collector. Using a simple scaling analysis, we show how the straightness and the diameter of the wires can be controlled by the electric field and the distance of the spinneret to the collector. A small inter-wire spacing, as predicted by a simple model, was achieved by simultaneously controlling the linear speed of the spinneret and the rotational speed of the collector. Rapid drying of the polymer nanowires enabled the facile fabrication of suspended wires over various structures. Patterned polyacrylonitrile wires were carbonized using standard stabilization and pyrolysis to obtain carbon nanowires. Suspended carbon nanowires with a diameter of <50 nm were obtained. We also established a method for making patterned, highly graphitized structures by using the aforementioned carbon wire structures as a template for chemical vapor deposition of graphite. This patterning technique offers high throughput for nano writing, which outperforms other existing nanopatterning techniques, making it a potential candidate for large-scale carbon nanomanufacturing.

Layered 3D Printing by Tethered Pyro-Electrospinning

Nowadays it is easy to imagine that the exploitation of different additive manufacturing approaches could find use in regenerative medicine and frontiers nanotechnology with a strong interest in the development of in vivo bio-incubators that better replicate the tissue environment. Various electrospinning technologies have been exploited for the fabrication of composite polymeric architectures, where fibers have been used for the construction layer by layer of micro-architectures. Unfortunately, in case of processing biomaterials, the intrinsic factors of the materials could become obstacles when considering such advanced engineering methods. Here, for the first time, we use the pyro-EHD process for the fabrication of layered three-dimensional architectures made using a biodegradable and biocompatible polymer. The proposed approach for layered 3D printing works at mild temperature allowing deposition at high resolution and great flexibility in manufacturing, avoiding high voltage generators, and nozzles. The layered 3D printing, activated by the pyro-electric effect, is discussed and characterized in terms of geometrical features and processing parameters. Different geometries and micro-architecture (wall, square, triangle, and hybrid structures) have been demonstrated and over printing of composite polymer, obtained by mixing multiwall carbon nanotubes and fluorochrome, has been discussed, focusing on the use of a biodegradable and biocompatible polymer.

Fiber Scaffold Patterning for Mending Hearts: 3D Organization Bringing the Next Step

Heart failure (HF) is a leading cause of death worldwide. The most common conditions that lead to HF are coronary artery disease, myocardial infarction, valve disorders, high blood pressure, and cardiomyopathy. Due to the limited regenerative capacity of the heart, the only curative therapy currently available is heart transplantation. Therefore, there is a great need for the development of novel regenerative strategies to repair the injured myocardium, replace damaged valves, and treat occluded coronary arteries. Recent advances in manufacturing technologies have resulted in the precise fabrication of 3D fiber scaffolds with high architectural control that can support and guide new tissue growth, opening exciting new avenues for repair of the human heart. This review discusses the recent advancements in the novel research field of fiber patterning manufacturing technologies for cardiac tissue engineering (cTE) and to what extent these technologies could meet the requirements of the highly organized and structured cardiac tissues. Additionally, future directions of these novel fiber patterning technologies, designs, and applicability to advance cTE are presented.

A Parameter Study for 3D-Printing Organized Nanofibrous Collagen Scaffolds Using Direct-Write Electrospinning

Collagen-based scaffolds are gaining more prominence in the field of tissue engineering. However, readily available collagen scaffolds either lack the rigid structure (hydrogels) and/or the organization (biopapers) seen in many organ tissues, such as the cornea and meniscus. Direct-write electrospinning is a promising potential additive manufacturing technique for constructing highly ordered fibrous scaffolds for tissue engineering and foundational studies in cellular behavior, but requires specific process parameters (voltage, relative humidity, solvent) in order to produce organized structures depending on the polymer chosen. To date, no work has been done to optimize direct-write electrospinning parameters for use with pure collagen. In this work, a custom electrospinning 3D printer was constructed to derive optimal direct write electrospinning parameters (voltage, relative humidity and acetic acid concentrations) for pure collagen. A LabVIEW program was built to automate control of the print stage. Relative humidity and electrospinning current were monitored in real-time to determine the impact on fiber morphology. Fiber orientation was analyzed via a newly defined parameter (spin quality ratio (SQR)). Finally, tensile tests were performed on electrospun fibrous mats as a proof of concept.

Fabrication of Designable and Suspended Microfibers via Low-Voltage 3D Micropatterning

Building two-dimensional (2D) and three-dimensional (3D) fibrous structures in the micro- and nanoscale will offer exciting prospects for numerous applications spanning from sensors to energy storage and tissue engineering scaffolds. Electrospinning is a well-suited technique for drawing micro- to nanoscale fibers, but current methods of building electrospun fibers in 3D are restrictive in terms of printed height, design of macroscopic fiber networks, and choice of polymer. Here, we combine low-voltage electrospinning and additive manufacturing as a method to pattern layers of suspended mesofibers. Layers of fibers are suspended between 3D-printed supports in situ in multiple fiber layers and designable orientations. We examine the key working parameters to attain a threshold for fiber suspension, use those behavioral observations to establish a "fiber suspension indicator", and demonstrate its utility through design of intricate suspended fiber architectures. Individual fibers produced by this method approach the micrometer/submicrometer scale, while the overall suspended 3D fiber architecture can span over a centimeter in height. We demonstrate an application of suspended fiber architectures in 3D cell culture, utilizing patterned fiber topography to guide the assembly of suspended high-cellular-density structures. The solution-based fiber suspension patterning process we report offers a unique competence in patterning soft polymers, including extracellular matrix-like materials, in a high resolution and aspect ratio. The platform could thus offer new design and manufacturing capabilities of devices and functional products by incorporating functional fibrous elements.

Shear Force Fiber Spinning: Process Parameter and Polymer Solution Property Considerations

For application of polymer nanofibers (e.g., sensors, and scaffolds to study cell behavior) it is important to control the spatial orientation of the fibers. We compare the ability to align and pattern fibers using shear force fiber spinning, i.e. contacting a drop of polymer solution with a rotating collector to mechanically draw a fiber, with electrospinning onto a rotating drum. Using polystyrene as a model system, we observe that the fiber spacing using shear force fiber spinning was more uniform than electrospinning with the rotating drum with relative standard deviations of 18% and 39%, respectively. Importantly, the approaches are complementary as the fiber spacing achieved using electrospinning with the rotating drum was ~10 microns while fiber spacing achieved using shear force fiber spinning was ~250 microns. To expand to additional polymer systems, we use polymer entanglement and capillary number. Solution properties that favor large capillary numbers (>50) prevent droplet breakup to facilitate fiber formation. Draw-down ratio was useful for determining appropriate process conditions (flow rate, rotational speed of the collector) to achieve continuous formation of fibers. These rules of thumb for considering the polymer solution properties and process parameters are expected to expand use of this platform for creating hierarchical structures of multiple fiber layers for cell scaffolds and additional applications.

Shape Transformation Photolithography: Self-Assembled Arrays of Suspended MEMS Structures from Patterned Polymer Membranes

Suspended micromechanical structures are typically formed by dissolving underlying spacer material. However, capillary force-induced collapse during solvent removal can damage soft structures. If instead capillary forces are directed in the plane, they can drive liquid polymeric bridges to directly transform into suspended fibers. The various capillary force-directed methods for fabricating arrays of suspended fibers have suffered from either low manufacturing rates or an inability to produce arbitrary patterns. Shape transformation photolithography (STP) demonstrated herein is a method of producing arbitrarily patterned arrays of suspended fibers that are potentially capable of high fabrication rates. In STP, holes are prepatterned in a polymer nanofilm supported on a micropillar array, and then the film is heated above its glass transition temperature. First, the holes expand by dewetting and then capillary forces drive thinning of the polymer channels defined by the holes. Prepatterning overcomes the energy barrier for hole nucleation and ensures that all fibers form at the same time and with similar diameters. Arrays of fibers and fiber lattice networks are formed from dyed polystyrene films that are patterned with nanosecond laser pulses at 532 nm. The exposure threshold for forming holes is 10.5 mJ/cm² for single pulses and 3.3 mJ/cm² per pulse for repetitive pulsing, which is only about 3× larger than the dose available from current 193 nm wafer-stepping projection printers that are used in device manufacture. With the increased absorption of polystyrene at 193 nm and with additional proposed material modifications to the thin film, it may even be possible to employ STP in production wafer steppers at economically feasible manufacturing rates of over 50 wafers/h.

Solution fibre spinning technique for the fabrication of tuneable decellularised matrix-laden fibres and fibrous micromembranes

Recreating tissue-specific microenvironments of the extracellular matrix (ECM) in vitro is of broad interest for the fields of tissue engineering and organ-on-a-chip. Here, we present biofunctional ECM protein fibres and suspended membranes, with tuneable biochemical, mechanical and topographical properties. This soft and entirely biologic membrane scaffold, formed by micro-nano-fibres using low voltage electrospinning, displays three unique characteristics for potential cell culture applications: high-content of key ECM proteins, single-layered mesh membrane, and flexibility for in situ integration into a range of device setups. Extracellular matrix (ECM) powder derived from urinary bladder, was used to fabricate the ECM-laden fibres and membranes. The highest ECM concentration in the dry protein fibre was 50 wt%, with the rest consisting of gelatin. Key ECM proteins, including collagen IV, laminin, and fibronectin, were shown to be preserved post the biofabrication process. The single fibre tensile Young's modulus can be tuned for over two orders of magnitude between ∼600 kPa and 50 MPa depending on the ECM content. Combining the fibre mesh printing with 3D printed or microfabricated structures, culture devices were constructed for endothelial layer formation, and a trans-membrane co-culture formed by glomerular cell types of podocytes and glomerular endothelial cells, demonstrating feasibility of the membrane culture. Our cell culture observation points to the importance of membrane mechanical property and re-modelling ability as a factor for soft membrane-based cell cultures. The ECM-laden fibres and membranes presented here would see potential applications in in vitro assays, and tailoring structure and biological functions of tissue engineering scaffolds.

STATEMENT OF SIGNIFICANCE

Recreating tissue-specific microenvironments of the extracellular matrix (ECM) is of broad interest for the fields of tissue engineering and organ-on-a-chip. Both the biochemical and biophysical signatures of the engineered ECM interplay to affect cell response. Currently, there are limited biomaterials processing methods which allow to design ECM membrane properties flexibly and rapidly. Solvents and additives used in many existing processes also induced unwanted ECM protein degradation and toxic residues. This paper presents a solution fibre spinning technique, where careful selection of the solution combination led to well-preserved ECM proteins with tuneable composition. This technique also provides a highly versatile approach to fabricate ECM fibres and membranes, leading to designable fibre Young's modulus for over two orders of magnitude.

Multi-length scale bioprinting towards simulating microenvironmental cues

It is envisaged that the creation of cellular environments at multiple length scales, that recapitulate in vivo bioactive and structural roles, may hold the key to creating functional, complex tissues in the laboratory. This review considers recent advances in biofabrication and bioprinting techniques across different length scales. Particular focus is placed on 3D printing of hydrogels and fabrication of biomaterial fibres that could extend the feature resolution and material functionality of soft tissue constructs. The outlook from this review discusses how one might create and simulate microenvironmental cues in vitro. A fabrication platform that integrates the competencies of different biofabrication technologies is proposed. Such a multi-process, multiscale fabrication strategy may ultimately translate engineering capability into an accessible life sciences toolkit, fulfilling its potential to deliver in vitro disease models and engineered tissue implants.

Novel Deep-Eutectic-Solvent-Infused Carbon Nanofiber Networks as High Power Density Green Battery Cathodes

Redox flow batteries (RFBs) have emerged as a promising candidate for large-scale energy storage because of the flexible design for high energy, power, and safety. In this study, FeCl₃·6H₂O/urea composite deep eutectic catholyte (FeU-DEC)-infused self-standing carbon nanofiber (CNF) was synthesized for green and high power density RFB through industrially available processes. FeU-DEC-infused CNF displayed an extremely high power density (874 mW/g) as well as high capacity (27.28 mAh/g) derived from high theoretical capacity of FeU-DEC (89.24 mAh/g) in addition to the advantages of the FeU-DEC characteristics (e.g., nonflammable, biodegradable, facile preparation). This is because of the large electroactive area derived from the high surface area of CNF and superlyophilicity of FeU-DEC on CNFs. Furthermore, we compared the wettability of CNF with other electrodes, as well as the chemical stability and electrode performance, based on topological wetting analysis using parameters of fiber radius, fiber interval, the equilibrium contact angle of FeU-DEC on electrodes, and surface tension of FeU-DEC, giving wetting threshold for FeU-DEC on fibrous electrodes. The wetting analysis are applied not only for FeU-DEC, but also for a wide range of other DECs and deep eutectic anolyte. This work contributes to the further development of green and high-performance RFBs.

Large-Scale Direct-Writing of Aligned Nanofibers for Flexible Electronics

Nanofibers/nanowires usually exhibit exceptionally low flexural rigidities and remarkable tolerance against mechanical bending, showing superior advantages in flexible electronics applications. Electrospinning is regarded as a powerful process for this 1D nanostructure; however, it can only be able to produce chaotic fibers that are incompatible with the well-patterned microstructures in flexible electronics. Electro-hydrodynamic (EHD) direct-writing technology enables large-scale deposition of highly aligned nanofibers in an additive, noncontact, real-time adjustment, and individual control manner on rigid or flexible, planar or curved substrates, making it rather attractive in the fabrication of flexible electronics. In this Review, the ground-breaking research progress in the field of EHD direct-writing technology is summarized, including a brief chronology of EHD direct-writing techniques, basic principles and alignment strategies, and applications in flexible electronics. Finally, future prospects are suggested to advance flexible electronics based on orderly arranged EHD direct-written fibers. This technology overcomes the limitations of the resolution of fabrication and viscosity of ink of conventional inkjet printing, and represents major advances in manufacturing of flexible electronics.

Emerging Roles of Electrospun Nanofibers in Cancer Research

This article reviews the recent progress of electrospun nanofibers in cancer research. It begins with a brief introduction to the emerging potential of electrospun nanofibers in cancer research. Next, a number of recent advances on the important features of electrospun nanofibers critical for cancer research are discussed including the incorporation of drugs, control of release kinetics, orientation and alignment of nanofibers, and the fabrication of 3D nanofiber scaffolds. This article further highlights the applications of electrospun nanofibers in several areas of cancer research including local chemotherapy, combinatorial therapy, cancer detection, cancer cell capture, regulation of cancer cell behavior, construction of in vitro 3D cancer model, and engineering of bone microenvironment for cancer metastasis. This progress report concludes with remarks on the challenges and future directions for design, fabrication, and application of electrospun nanofibers in cancer diagnostics and therapeutics.

Novel Antimicrobial Titanium Dioxide Nanotubes Obtained through a Combination of Atomic Layer Deposition and Electrospinning Technologies

The search for new antimicrobial substances has increased in recent years. Antimicrobial nanostructures are one of the most promising alternatives. In this work, titanium dioxide nanotubes were obtained by an atomic layer deposition (ALD) process over electrospun polyvinyl alcohol nanofibers (PVN) at different temperatures with the purpose of obtaining antimicrobial nanostructures with a high specific area. Electrospinning and ALD parameters were studied in order to obtain PVN with smallest diameter and highest deposition rate, respectively. Chamber temperature was a key factor during ALD process and an appropriate titanium dioxide deposition performance was achieved at 200 °C. Subsequently, thermal and morphological analysis by SEM and TEM microscopies revealed hollow nanotubes were obtained after calcination process at 600 °C. This temperature allowed complete polymer removal and influenced the resulting anatase crystallographic structure of titanium dioxide that positively affected their antimicrobial activities. X-ray analysis confirmed the change of titanium dioxide crystallographic structure from amorphous phase of deposited PVN to anatase crystalline structure of nanotubes. These new nanostructures with very large surface areas resulted in interesting antimicrobial properties against Gram-positive and Gram-negative bacteria. Titanium dioxide nanotubes presented the highest activity against Escherichia coli with 5 log cycles reduction at 200 μg/mL concentration.

Double anisotropic electrically conductive flexible Janus-typed membranes

Novel type III anisotropic conductive films (ACFs), namely flexible Janus-typed membranes, were proposed, designed and fabricated for the first time. Flexible Janus-typed membranes composed of ordered Janus nanobelts were constructed by electrospinning, which simultaneously possess fluorescence and double electrically conductive anisotropy. For the fabrication of the Janus-typed membrane, Janus nanobelts comprising a conductive side and an insulative-fluorescent side were primarily fabricated, and then the Janus nanobelts are arranged into parallel arrays using an aluminum rotary drum as the collector to obtain a single anisotropically conductive film. Subsequently, a secondary electrospinning process was applied to the as-prepared single anisotropically conductive films to acquire the final Janus-typed membrane. For this Janus-typed membrane, namely its left-to-right structure, anisotropic electrical conduction synchronously exists on both sides, and furthermore, the two electrically conductive directions are perpendicular. By modulating the amount of Eu(BA)₃phen complex and conducting polyaniline (PANI), the characteristics and intensity of the fluorescence-electricity dual-function in the membrane can be tuned. The high integration of this peculiar Janus-typed membrane with simultaneous double electrically conductive anisotropy-fluorescent dual-functionality is successfully realized in this study. This design philosophy and preparative technique will provide support for the design and construction of new types of special nanostructures with multi-functionality.

Toward High Conductivity of Electrospun Indium Tin Oxide Nanofibers with Fiber Morphology Dependent Surface Coverage: Postannealing and Polymer Ratio Effects

High electrical conductivity of metal oxide thin films needs uniform surface coverage, which has been the issue for the thin films based on electrospun nanofibers (NFs) that have advantage over the sputtered/spin-coated films with respect to large surface area and mechanical flexibility. Herein, we investigated a reduction in the sheet resistance of electrospun indium tin oxide (ITO) NF films with improved surface coverage. We found that the surface coverage depends significantly on the electrospinnable polymer concentration in the precursor solutions, especially after post-hot-plate annealing following the infrared radiation furnace treatment. The postannealing process increases crystallinity and oxygen vacancies. However, with a higher PVP content, it makes the surface of ITO NFs more prominently rough as a result of the formation of larger sphere-shaped ITO particles on the NF surface, which gives rise to poor surface coverage. A less poly(vinylpyrrolidone) (PVP) content in ITO NF films by electrospinning for short deposition times was found to improve surface coverage even after postannealing. The sheet resistance notably decreases, down to as low as 350 Ω/sq, with a high transmittance of over 90%. Our study provides an understanding on how to achieve high electrical conductivity of ITO NF films with high surface coverage, which can be utilized for the optoelectronic and sensing applications.

Direct Writing of Microfluidic Footpaths by Pyro-EHD Printing

In this study, we report a direct writing method for the fabrication of microfluidic footpaths by pyro-electrohydrodynamic (EHD) jet printing. Here, we propose the use of a nozzle-free three-dimensional printing technique for the fabrication of printed structures that can be embedded in a variety of soft, transparent, flexible, and biocompatible polymers and thus easily integrated into lab-on-chip devices. We prove the advantage of the high resolution and flexibility of pyro-EHD printing for the realization of microfluidic channels well below the standard limit in dimension of conventional ink-jet printing technique and simply adaptable to the end-user desires in terms of geometry and materials. Starting from the description of the innovative approach proposed for the channel fabrication, we demonstrate the design, fabrication, and proof of a microfluidic matrix of interconnected channels. The method described here could be a breakthrough technology for the fabrication of in situ implantable, stretchable, and biocompatible devices, opening new routes in the field of biomedical engineering and wearable electronics.