Charting the envelope of mechanical properties of synthetic silk fibers through predictive modeling of the drawing process

A major challenge in synthesizing strong and tough protein fibers based on spider silk motifs is understanding the coupling between protein sequence and the postspin drawing process. We clarify how drawing-induced elongational force affects ordering, chain extension, interchain contacts, and molecular mobility through mesoscale simulations of silk-based fibers. We show that these emergent features can be used to predict mechanical property enhancements arising from postspin drawing. Simulations recapitulate a purely process-dependent mechanical property envelope in which order enhances fiber strength while preserving toughness. The relationship between chain extension and crystalline domain alignment observed in simulations is validated by Raman spectroscopy of wet-spun fibers. Property enhancements attributed to the progression of anisotropic extension are verified by mechanical tests of drawn silk fibers and justified by theory. These findings elucidate how drawing enhances properties of protein-based fibers and shed light on how to incorporate this effect into predictive models.

Post-spin Stretch Improves Mechanical Properties, Reduces Necking, and Reverts Effects of Aging in Biomimetic Artificial Spider Silk Fibers

Recent biotechnological advancements in protein production and development of biomimetic spinning procedures make artificial spider silk a promising alternative to petroleum-based fibers. To enhance the competitiveness of artificial silk in terms of mechanical properties, refining the spinning techniques is imperative. One potential strategy involves the integration of post-spin stretching, known to improve fiber strength and stiffness while potentially offering additional advantages. Here, we demonstrate that post-spin stretching not only enhances the mechanical properties of artificial silk fibers but also restores a higher and more uniform alignment of the protein chains, leading to a higher fiber toughness. Additionally, fiber properties may be reduced by processes, such as aging, that cause increased network entropy. Post-spin stretching was found to partially restore the initial properties of fibers exposed aging. Finally, we propose to use the degree of necking as a simple measure of fiber quality in the development of spinning procedures for biobased fibers.

Overexpression of bond-forming active protein for efficient production of silk with structural changes and properties enhanced in silkworm

Silkworm silk exhibits excellent mechanical properties, biocompatibility, and has potential applications in the biomedical sector. This study focused on enhancing the mechanical properties of Bombyx mori silk by overexpressing three bond-forming active proteins (BFAPs): AFP, HSP, and CRP in the silk glands of silkworms. Rheological tests confirmed increased viscoelasticity in the liquid fibroin stock solution of transgenic silkworms, and dynamic mechanical thermal analysis (DMTA) indicated that all three BFAPs participated in the interactions between fibroin molecular networks in transgenic silk. The mechanical property assay indicated that all three BFAPs improved the mechanical characteristics of transgenic silk, with AFP and HSP having the most significant effects. A synchrotron radiation Fourier transform infrared spectroscopy assay showed that all three BFAPs increased the β-sheet content of transgenic silk. Synchrotron radiation wide-angle X-ray diffraction assay showed that all three BFAPs changed the crystallinity, crystal size, and orientation factor of the silk. AFP and HSP significantly improved the mechanical attributes of transgenic silk through increased crystallinity, refined crystal size, and a slight decrease in orientation. This study opens new possibilities for modifying silk and other fiber materials.

Spidroins under the Influence of Alcohol: Effect of Ethanol on Secondary Structure and Molecular Level Solvation of Silk-Like Proteins

Future sustainable materials based on designer biomolecules require control of the solution assembly, but also interfacial interactions. Alcohol treatments of protein materials are an accessible means to this, making understanding of the process at the molecular level of seminal importance. We focus here on the influence of ethanol on spidroins, the main proteins of silk. By large-scale atomistically detailed molecular dynamics (MD) simulations and interconnected experiments, we characterize the protein aggregation, secondary structure changes, molecular level origins of them, and solvation environment changes for the proteins, as induced by ethanol as a solvation additive. The MD and circular dichoroism (CD) findings jointly show that ethanol promotes ordered structure in the protein molecules, leading to an increase of helix content and turns but also increased aggregation, as revealed by dynamic light scattering (DLS) and light microscopy. The structural changes correlate at the molecular level with increased intramolecular hydrogen bonding. The simulations reveal that polar amino acids, such as glutamine and serine, are most influenced by ethanol, whereas glycine residues are most prone to be involved in the ethanol-induced secondary structure changes. Furthermore, ethanol engages in interactions with the hydrophobic alanine-rich regions of the spidroin, significantly decreasing the hydrophobic interactions of the protein with itself and its surroundings. The protein solutes also change the microstructure of water/ethanol mixtures, essentially decreasing the level of larger local clustering. Overall, the work presents a systematic characterization of ethanol effects on a widely used, common protein type, spidroins, and generalizes the findings to other intrinsically disordered proteins by pinpointing the general features of the response. The results can aid in designing effective alcohol treatments for proteins, but also enable design and tuning of protein material properties by a relatively controllable solvation handle, the addition of ethanol.

Electrospun Nanofibrous UV Filters with Bidirectional Actuation Properties Based on Salmon Sperm DNA/Silk Fibroin for Biomedical Applications

In this study, we dissolved Bombyx mori degummed silk [i.e., silk fibroin (SF)] and salmon sperm deoxyribonucleic acid (DNA) in water and used a bioinspired spinning process to obtain an electrospun nanofibrous SF-based patch (ESF). We investigated the bidirectional macroscale actuation behavior of ESF in response to water vapor and its UV-blocking properties as well as those of ESF/DNA films. Fourier transform infrared (FTIR) results suggest that the formation of β-sheet-rich structures promotes the actuation effect. ESF/DNA film with high-ordered and β-sheet-rich structures exhibits higher electrical conductivity and is water-insoluble. Given the intrinsic ability of both SF and DNA to absorb UV radiation, we performed biological experiments on the viability of keratinocyte HaCaT cells after exposure to solar spectrum components. Our findings indicate that the ESF/DNA patch is photoprotective and can increase the cellular viability of keratinocytes after UV exposure. Furthermore, we demonstrated that ESF/DNA patches treated with water vapor can serve as suitable scaffolds for tissue engineering and can improve tissue regeneration when cellularized with HaCaT cells. The 3D shape morphing capability of these patches, along with their potential as UV filters, could offer significant practical advantages in tissue engineering.

Pulling and analyzing silk fibers from aqueous solution using a robotic device

Spiders, silkworms, and many other animals can spin silk with exceptional properties. However, artificially spun fibers often fall short of their natural counterparts partly due sub-optimal production methods. A variety of methods, such as wet-, dry-, and biomimetic spinning have been used. The methods are based on extrusion, whereas natural spinning also involves pulling. Another shortcoming is that there is a lack feedback control during extension. Here we demonstrate a robotic fiber pulling device that enables controlled pulling of silk fibers and in situ measurement of extensional forces during the pulling and tensile testing of the pulled fibers. The pulling device was used to study two types of silk-one recombinant spider silk (a structural variant of ADF3) and one regenerated silk fibroin. Also, dextran-a branched polysaccharide-was used as a reference material for the procedure due to its straightforward preparation and storage. No post-treatments were applied. The pulled regenerated silk fibroin fibers achieved high tensile strength in comparison to similar extrusion-based methods. The mechanical properties of the recombinant spider silk fibers seemed to be affected by the liquid-liquid phase separation of the silk proteins.

Tailoring micro/nano-fibers for biomedical applications

Nano/micro fibers have evoked much attention of scientists and have been researched as cutting edge and hotspot in the area of fiber science in recent years due to the rapid development of various advanced manufacturing technologies, and the appearance of fascinating and special functions and properties, such as the enhanced mechanical strength, high surface area to volume ratio and special functionalities shown in the surface, triggered by the nano or micro-scale dimensions. In addition, these outstanding and special characteristics of the nano/micro fibers impart fiber-based materials with wide applications, such as environmental engineering, electronic and biomedical fields. This review mainly focuses on the recent development in the various nano/micro fibers fabrication strategies and corresponding applications in the biomedical fields, including tissue engineering scaffolds, drug delivery, wound healing, and biosensors. Moreover, the challenges for the fabrications and applications and future perspectives are presented.

A Protein-Like Nanogel for Spinning Hierarchically Structured Artificial Spider Silk

Spider dragline silk is draw-spun from soluble, β-sheet-crosslinked spidroin in aqueous solution. This spider silk has an excellent combination of strength and toughness, which originates from the hierarchical structure containing β-sheet crosslinking points, spiral nanoassemblies, a rigid sheath, and a soft core. Inspired by the spidroin structure and spider spinning process, a soluble and crosslinked nanogel is prepared and crosslinked fibers are drew spun with spider-silk-like hierarchical structures containing cross-links, aligned nanoassemblies, and sheath-core structures. Introducing nucleation seeds in the nanogel solution, and applying prestretch and a spiral architecture in the nanogel fiber, further tunes the alignment and assembly of the polymer chains, and enhances the breaking strength (1.27 GPa) and toughness (383 MJ m^-3 ) to approach those of the best dragline silk. Theoretical modeling provides understanding for the dependence of the fiber's spinning capacity on the nanogel size. This work provides a new strategy for the direct spinning of tough fiber materials.

Spider Silk-Inspired Artificial Fibers

Spider silk is a natural polymeric fiber with high tensile strength, toughness, and has distinct thermal, optical, and biocompatible properties. The mechanical properties of spider silk are ascribed to its hierarchical structure, including primary and secondary structures of the spidroins (spider silk proteins), the nanofibril, the "core-shell", and the "nano-fishnet" structures. In addition, spider silk also exhibits remarkable properties regarding humidity/water response, water collection, light transmission, thermal conductance, and shape-memory effect. This motivates researchers to prepare artificial functional fibers mimicking spider silk. In this review, the authors summarize the study of the structure and properties of natural spider silk, and the biomimetic preparation of artificial fibers from different types of molecules and polymers by taking some examples of artificial fibers exhibiting these interesting properties. In conclusion, biomimetic studies have yielded several noteworthy findings in artificial fibers with different functions, and this review aims to provide indications for biomimetic studies of functional fibers that approach and exceed the properties of natural spider silk.

Microbially Synthesized Polymeric Amyloid Fiber Promotes β-Nanocrystal Formation and Displays Gigapascal Tensile Strength

The ability of amyloid proteins to form stable β-sheet nanofibrils has made them potential candidates for material innovation in nanotechnology. However, such a nanoscale feature has rarely translated into attractive macroscopic properties for mechanically demanding applications. Here, we present a strategy by fusing amyloid peptides with flexible linkers from spidroin; the resulting polymeric amyloid proteins can be biosynthesized using engineered microbes and wet-spun into macroscopic fibers. Using this strategy, fibers from three different amyloid groups were fabricated. Structural analyses unveil the presence of β-nanocrystals that resemble the cross-β structure of amyloid nanofibrils. These polymeric amyloid fibers have displayed strong and molecular-weight-dependent mechanical properties. Fibers made of a protein polymer containing 128 repeats of the FGAILSS sequence displayed an average ultimate tensile strength of 0.98 ± 0.08 GPa and an average toughness of 161 ± 26 MJ/m³, surpassing most recombinant protein fibers and even some natural spider silk fibers. The design strategy and the biosynthetic approach can be expanded to create numerous functional materials, and the macroscopic amyloid fibers will enable a wide range of mechanically demanding applications.

Silk Fibroin As an Immobilization Matrix for Sensing Applications

The development of flexible, biocompatible, and environment-friendly sensors has attracted a significant amount of scientific interest for the past few decades. Among all the natural materials, silk fibroin (SF), due to its tunable biodegradability, biocompatibility, ease of processing, presence of functional groups, and controllable dimensions, has opened up opportunities for immobilizing multitudinous biomolecules and conformability to the skin, among other attractive opportunities. The silk fibroins also offer good physical properties, such as superior toughness and tensile strength. The sensors made of SF as an immobilization matrix have demonstrated excellent analytical performance, sensing even at low concentrations. The significant advantage of silk fibroins is the presence of functional groups along with a controllable conformation transition that enables immobilization of receptor molecules using silk fibroins as an immobilization matrix enables us to entrap the receptor molecules without using any chemical reagents. This review encompasses a detailed discussion on sensors, the advantages of using silk fibroins as an immobilization matrix for various receptors, their applications, and the future research scope in this state-of-the-art technology based upon the explorable applications for silk fibroin-based sensors.

Review of microfluidic approaches for fabricating intelligent fiber devices: importance of shape characteristics

Shape characteristics, which include the physical dimensions (scale), apparent morphology, surface features, and structure, are essential factors of fibrous materials and determine many of their properties. Microfluidic technologies have recently been proposed as an approach for producing one-dimensional (1D) fibers with controllable shape characteristics and particle alignment, which impart specific functionality to the fiber. Moreover, superfine 1D fibers with a high surface area and ordered structure have many potential applications as they can be directly braided or woven into textiles, clothes, and tissues with two- or three-dimensional (2D or 3D) structures. Previous reviews of microfluidic spinning have not focus on the importance of the shape characteristic on fiber performance and their use in intelligent fiber design. Here, the latest achievements in microfluidic approaches for fiber-device fabrication are reviewed considering the underlying preparation principles, shape characteristics, and functionalization of the fibers. Additionally, intelligent fiber devices with shapes tailored by microfluidic approaches are discussed, including 1D sensors and actuators, luminous fibers, and devices for encoding, energy harvesting, water collection, and tissue engineering applications. Finally, recent progress, challenges, and future perspectives of the microfluidic approaches for fiber device fabrication are discussed.

Transgenic and Diet-Enhanced Silk Production for Reinforced Biomaterials: A Metamaterial Perspective

Silk fibers, which are protein-based biopolymers produced by spiders and silkworms, are fascinating biomaterials that have been extensively studied for numerous biomedical applications. Silk fibers often have remarkable physical and biological properties that typical synthetic materials do not exhibit. These attributes have prompted a wide variety of silk research, including genetic engineering, biotechnological synthesis, and bioinspired fiber spinning, to produce silk proteins on a large scale and to further enhance their properties. In this review, we describe the basic properties of spider silk and silkworm silk and the important production methods for silk proteins. We discuss recent advances in reinforced silk using silkworm transgenesis and functional additive diets with a focus on biomedical applications. We also explain that reinforced silk has an analogy with metamaterials such that user-designed atypical responses can be engineered beyond what naturally occurring materials offer. These insights into reinforced silk can guide better engineering of superior synthetic biomaterials and lead to discoveries of unexplored biological and medical applications of silk.

Microfluidic Silk Fibers with Aligned Hierarchical Microstructures

The hierarchical structure of the ECM provides specific niches for tissues to regulate cell behavior, yet the challenge remains to design biomaterial systems for tissue regeneration to recreate such features in vitro. Here, we achieved this goal through the use of aligned hierarchical structures of native silk fibers, generated through the integration of "bottom-up" and "top-down" strategies to generate regenerated silk fibers with aligned nano- to micro-hierarchical structures. To achieve these designs, we assembled and dispersed silk nanofibers (SNF) in formic acid and spun them into fibers using bioinspired microfluidic chips with a geometry mimicking the native silk gland. The fibers generated using this device exhibited aligned hierarchical structure with fiber mechanical properties superior to fibers derived from more traditional spinning approaches with regenerated silk solutions. Besides the improved mechanical properties, Raman spectroscopic results indicated similarly aligned structures to native fibers and active control of cell proliferation, migration, and aggregate orientation. The results indicate the feasibility of developing bioactive silk fiber materials with hierarchical structures to facilitate utility in a range of cell and tissue regeneration scenarios.

Artificial ligament made from silk protein/Laponite hybrid fibers

With developments in tissue engineering, artificial ligaments are expected to be future materials for anterior cruciate ligament (ACL) reconstruction. However, poor healing of the intraosseous part after ACL reconstruction significantly hinders their applications in this field. In this study, a bioactive clay Laponite (LAP) was introduced into the regenerated silk fibroin (RSF) spinning dope to produce functional RSF/LAP hybrid fibers by wet-spinning. These RSF/LAP hybrid fibers were then woven into artificial ligament for ACL reconstruction. The structure and mechanical properties of RSF/LAP hybrid fibers were extensively studied by different means. Results confirmed the presence of LAP in RSF fibers and revealed that the addition of LAP slightly deteriorated the comprehensive mechanical properties of RSF fibers. However, they were still much tougher (with higher breaking energy) than those of degummed natural silkworm silk that was earlier used for making artificial ligament. The artificial ligament woven from RSF/LAP hybrid fibers showed better cytocompatibility and osteogenic differentiation with mouse pre-osteoblasts in vitro than those made from degummed natural silkworm silks and pure RSF fibers. Furthermore, in vivo study in a rat ACL reconstruction model demonstrated that the presence of LAP in the artificial ligament could significantly enhance the graft osseointegration process and also improve the corresponding biomechanical properties of the artificial ligament. Based upon these results, the RSF/LAP hybrid fibers, which can be mass produced by wet-spinning process, are believed to have a great potential for use as artificial ligament materials for ACL reconstruction. STATEMENT OF SIGNIFICANCE: In this study, we successfully introduced Laponite (LAP), a kind of clay that has the function of osteogenic induction, into regenerated silk fibroin (RSF) fibers, which was prepared by a mature wet-spinning method developed in our lab. We believe that through artificial spinning, additional functional components can be added into RSF fibers, which one can hardly achieve with natural silks. We showed that the artificial ligament woven from RSF/LAP hybrid fibers had better cytocompatibility and osteogenic differentiation for mouse pre-osteoblasts in vitro, and significantly enhanced the graft osseointegration process and improved the corresponding biomechanical properties in a rat ACL reconstruction model in vivo, compared to those artificial ligaments made from degummed natural silkworm silks and pure RSF fibers.

Determination of the Complete Elasticity of Nephila pilipes Spider Silk

Spider silks are remarkable materials designed by nature to have extraordinary elasticity. Their elasticity, however, remains poorly understood, as typical stress–strain experiments only allow access to the axial Young’s modulus. In this work, micro-Brillouin light spectroscopy (micro-BLS), a noncontact, nondestructive technique, is utilized to probe the direction-dependent phonon propagation in the Nephila pilipes spider silk and hence solve its full elasticity. To the best of our knowledge, this is the first demonstration on the determination of the anisotropic Young’s moduli, shear moduli, and Poisson’s ratios of a single spider fiber. The axial and lateral Young’s moduli are found to be 20.9 ± 0.8 and 9.2 ± 0.3 GPa, respectively, and the anisotropy of the Young’s moduli further increases upon stretching. In contrast, the shear moduli and Poisson’s ratios exhibit very weak anisotropy and are robust to stretching.

Hierarchical Structure of Silk Materials Versus Mechanical Performance and Mesoscopic Engineering Principles

A comprehensive review on the five levels of hierarchical structures of silk materials and the correlation with macroscopic properties/performance of the silk materials, that is, the toughness, strain-stiffening, etc., is presented. It follows that the crystalline binding force turns out to be very important in the stabilization of silk materials, while the β-crystallite networks or nanofibrils and the interactions among helical nanofibrils are two of the most essential structural elements, which to a large extent determine the macroscopic performance of various forms of silk materials. In this context, the characteristic structural factors such as the orientation, size, and density of β-crystallites are very crucial. It is revealed that the formation of these structural elements is mainly controlled by the intermolecular nucleation of β-crystallites. Consequently, the rational design and reconstruction of silk materials can be implemented by controlling the molecular nucleation via applying sheering force and seeding (i.e., with carbon nanotubes). In general, the knowledge of the correlation between hierarchical structures and performance provides an understanding of the structural reasons behind the fascinating behaviors of silk materials.

Spinning and Applications of Bioinspired Fiber Systems

Natural fiber systems provide inspirations for artificial fiber spinning and applications. Through a long process of trial and error, great progress has been made in recent years. The natural fiber itself, especially silks, and the formation mechanism are better understood, and some of the essential factors are implemented in artificial spinning methods, benefiting from advanced manufacturing technologies. In addition, fiber-based materials produced via bioinspired spinning methods find an increasingly wide range of biomedical, optoelectronic, and environmental engineering applications. This paper reviews recent developments in the spinning and application of bioinspired fiber systems, introduces natural fiber and spinning processes and artificial spinning methods, and discusses applications of artificial fiber materials. Views on remaining challenges and the perspective on future trends are also proposed.

Recombinant Silk Fiber Properties Correlate to Prefibrillar Self-Assembly

Spider silks are desirable materials with mechanical properties superior to most synthetic materials coupled with biodegradability and biocompatibility. In order to replicate natural silk properties using recombinant spider silk proteins (spidroins) and wet-spinning methods, the focus to date has typically been on modifying protein sequence, protein size, and spinning conditions. Here, an alternative approach is demonstrated. Namely, using the same ≈57 kDa recombinant aciniform silk protein with a consistent wet-spinning protocol, fiber mechanical properties are shown to significantly differ as a function of the solvent used to dissolve the protein at high concentration (the "spinning dope" solution). A fluorinated acid/alcohol/water dope leads to drastic improvement in fibrillar extensibility and, correspondingly, toughness compared to fibers produced using a previously developed fluorinated alcohol/water dope. To understand the underlying cause for these mechanical differences, morphology and structure of the two classes of silk fiber are compared, with features tracing back to dope-state protein structuring and preassembly. Specifically, distinct classes of spidroin nanoparticles appear to form in each dope prior to fiber spinning and these preassembled states are, in turn, linked to fiber morphology, structure, and mechanical properties. Tailoring of dope-state spidroin nanoparticle assembly, thus, appears a promising strategy to modulate fibrillar silk properties.

Protein-Based Fiber Materials in Medicine: A Review

Fibrous materials have garnered much interest in the field of biomedical engineering due to their high surface-area-to-volume ratio, porosity, and tunability. Specifically, in the field of tissue engineering, fiber meshes have been used to create biomimetic nanostructures that allow for cell attachment, migration, and proliferation, to promote tissue regeneration and wound healing, as well as controllable drug delivery. In addition to the properties of conventional, synthetic polymer fibers, fibers made from natural polymers, such as proteins, can exhibit enhanced biocompatibility, bioactivity, and biodegradability. Of these proteins, keratin, collagen, silk, elastin, zein, and soy are some the most common used in fiber fabrication. The specific capabilities of these materials have been shown to vary based on their physical properties, as well as their fabrication method. To date, such fabrication methods include electrospinning, wet/dry jet spinning, dry spinning, centrifugal spinning, solution blowing, self-assembly, phase separation, and drawing. This review serves to provide a basic knowledge of these commonly utilized proteins and methods, as well as the fabricated fibers’ applications in biomedical research.

Polymorphic regenerated silk fibers assembled through bioinspired spinning

A variety of artificial spinning methods have been applied to produce regenerated silk fibers; however, how to spin regenerated silk fibers that retain the advantages of natural silks in terms of structural hierarchy and mechanical properties remains challenging. Here, we show a bioinspired approach to spin regenerated silk fibers. First, we develop a nematic silk microfibril solution, highly viscous and stable, by partially dissolving silk fibers into microfibrils. This solution maintains the hierarchical structures in natural silks and serves as spinning dope. It is then spun into regenerated silk fibers by direct extrusion in the air, offering a useful route to generate polymorphic and hierarchical regenerated silk fibers with physical properties beyond natural fiber construction. The materials maintain the structural hierarchy and mechanical properties of natural silks, including a modulus of 11 ± 4 GPa, even higher than natural spider silk. It can further be functionalized with a conductive silk/carbon nanotube coating, responsive to changes in humidity and temperature.

Precise correlation of macroscopic mechanical properties and microscopic structures of animal silks—using Antheraea pernyi silkworm silk as an example

The structure of wild silkworm silk can be controlled by reeling rate, thus regulating its mechanical performance from close to spider dragline silk to domestic silkworm silk.

Microstructural evolution of regenerated silk fibroin/graphene oxide hybrid fibers under tensile deformation

The stress–strain curve and proposed model of microstructural change of silk fibroin/GO hybrid fibers during the stretching deformation.

Recombinant spider silk from aqueous solutions via a bio-inspired microfluidic chip

Spiders achieve superior silk fibres by controlling the molecular assembly of silk proteins and the hierarchical structure of fibres. However, current wet-spinning process for recombinant spidroins oversimplifies the natural spinning process. Here, water-soluble recombinant spider dragline silk protein (with a low molecular weight of 47 kDa) was adopted to prepare aqueous spinning dope. Artificial spider silks were spun via microfluidic wet-spinning, using a continuous post-spin drawing process (WS-PSD). By mimicking the natural spinning apparatus, shearing and elongational sections were integrated in the microfluidic spinning chip to induce assembly, orientation of spidroins, and fibril structure formation. The additional post-spin drawing process following the wet-spinning section partially mimics the spinning process of natural spider silk and substantially contributes to the compact aggregation of microfibrils. Subsequent post-stretching further improves the hierarchical structure of the fibres, including the crystalline structure, orientation, and fibril melting. The tensile strength and elongation of post-treated fibres reached up to 510 MPa and 15%, respectively.

Regenerated silk materials for functionalized silk orthopedic devices by mimicking natural processing

Silk fibers spun by silkworms and spiders exhibit exceptional mechanical properties with a unique combination of strength, extensibility and toughness. In contrast, the mechanical properties of regenerated silk materials can be tuned through control of the fabrication process. Here we introduce a biomimetic, all-aqueous process, to obtain bulk regenerated silk-based materials for the fabrication of functionalized orthopedic devices. The silk materials generated in the process replicate the nano-scale structure of natural silk fibers and possess excellent mechanical properties. The biomimetic materials demonstrate excellent machinability, providing a path towards the fabrication of a new family of resorbable orthopedic devices where organic solvents are avoided, thus allowing functionalization with bioactive molecules to promote bone remodeling and integration.

Identification of Wet-Spinning and Post-Spin Stretching Methods Amenable to Recombinant Spider Aciniform Silk

Spider silks are outstanding biomaterials with mechanical properties that outperform synthetic materials. Of the six fibrillar spider silks, aciniform (or wrapping) silk is the toughest through a unique combination of strength and extensibility. In this study, a wet-spinning method for recombinant Argiope trifasciata aciniform spidroin (AcSp1) is introduced. Recombinant AcSp1 comprising three 200 amino acid repeat units was solubilized in a 1,1,1,3,3,3-hexafluoro-2-propanol (HFIP)/water mixture, forming a viscous α-helix-enriched spinning dope, and wet-spun into an ethanol/water coagulation bath allowing continuous fiber production. Post-spin stretching of the resulting wet-spun fibers in water significantly improved fiber strength, enriched β-sheet conformation without complete α-helix depletion, and enhanced birefringence. These methods allow reproducible aciniform silk fiber formation, albeit with lower extensibility than native silk, requiring conditions and methods distinct from those previously reported for other silk proteins. This provides an essential starting point for tailoring wet-spinning of aciniform silk to achieve desired properties.

Exploration of the tight structural-mechanical relationship in mulberry and non-mulberry silkworm silks

The Bombyx mori silkworm is well known as it has been bred by our ancestors with mulberry tree leaves for thousands of years. However, Bombyx mori is not the only silkworm that can produce silk, many other kinds of silkworms can also make silks for commercial use. In this research, we compare the mechanical properties of five different commercial silk fibres including domesticated mulberry Bombyx mori, non-mulberry semi-domesticated eri Samia ricini, and wild tropical tasar Antheraea mylitta and muga Antheraea assamensis. The results demonstrate that the non-mulberry silk fibres have a relatively high extensibility as compared to the mulberry silk fibres. In the meantime, the non-mulberry silk fibres show comparatively unique toughness to the mulberry silk fibres. Synchrotron radiation FTIR microspectroscopy, synchrotron radiation wide angle X-ray diffraction, and Raman dichroism spectroscopy are used to analyze the structural differences among the five species of silk fibres comprehensively. The results clearly show that the mechanical properties of both mulberry and non-mulberry silk fibres are closely related to their structures, such as β-sheet content, crystallinity, and the molecular orientation along the fibre axis. This study aims to understand the differences in the structural and mechanical properties of different mulberry and non-mulberry silk fibres, which are of importance to the related research on understanding and utilizing the non-mulberry silk as a biomaterial. We believe these investigations not only provide insight into the biology of silk fibroins from the non-mulberry silkworms but also offer guidelines for further biomimetic investigations into the design and manufacture of artificial silk protein fibres with novel morphologies and associated material properties for future use in different fields like bioelectronics, biomaterials and biomedical devices.

Molecular Orientation Enhancement of Silk by the Hot-Stretching-Induced Transition from α-Helix-HFIP Complex to β-Sheet

Enhancing the molecular orientation of the regenerated silk fibroin (RF) up to a level comparable to the native silk is highly challenging. Our novel and promising strategy for the poststretching process is (1) creating at first an α-helix-HFIP complex with a hexagonal packing as an intermediate state and then (2) stretching it at a high temperature to induce the helix-to-sheet structural phase transition. Here we show for the first time the significantly high stretching efficiency of the proposed technique compared with the conventional wet-stretching techniques and the successful achievement of higher crystalline orientation and higher Young's modulus compared even with the native silk. The detailed structural analysis based on the time-resolved simultaneous measurement of stress-strain curve, synchrotron X-ray scatterings, and FTIR has revealed the structural transition mechanism from the hexagonally packed α-helix-HFIP complex to the highly oriented β-sheet crystalline state as well as the critical level of crystal orientation needed for the helix-to-sheet transition.

Hybrid Silk Fibers Dry-Spun from Regenerated Silk Fibroin/Graphene Oxide Aqueous Solutions

Regenerated silk fibroin (RSF)/graphene oxide (GO) hybrid silk fibers were dry-spun from a mixed dope of GO suspension and RSF aqueous solution. It was observed that the presence of GO greatly affect the viscosity of RSF solution. The RSF/GO hybrid fibers showed from FTIR result lower β-sheet content compared to that of pure RSF fibers. The result of synchrotron radiation wide-angle X-ray diffraction showed that the addition of GO confined the crystallization of silk fibroin (SF) leading to the decrease of crystallinity, smaller crystallite size, and new formation of interphase zones in the artificial silks. Synchrotron radiation small-angle X-ray scattering also proved that GO sheets in the hybrid silks and blended solutions were coated with a certain thickness of interphase zones due to the complex interaction between the two components. A low addition of GO, together with the mesophase zones formed between GO and RSF, enhanced the mechanical properties of hybrid fibers. The highest breaking stress of the hybrid fibers reached 435.5 ± 71.6 MPa, 23% improvement in comparison to that of degummed silk and 72% larger than that of pure RSF silk fiber. The hybrid RSF/GO materials with good biocompatibility and enhanced mechanical properties may have potential applications in tissue engineering, bioelectronic devices, or energy storage.

Tough protein-carbon nanotube hybrid fibers comparable to natural spider silks

Animal silks, especially spider dragline silks, have an excellent portfolio of mechanical properties, but it is still a challenge to obtain artificial silk fibers with similar properties to the natural ones. In this paper, we show how to extrude tough regenerated silk fibers by adding a small amount of commercially available functionalized multiwalled carbon nanotubes (less than 1%) through an environmentally friendly wet-spinning process reported by this laboratory previously. Most of the resulting regenerated silk fibers exhibited a breaking energy beyond 130 MJ m^-3, which is comparable to spider dragline silks (∼160 MJ m^-3). The best of these fibers in terms of performance show a breaking stress of 0.42 GPa, breaking strain of 59%, and breaking energy of 186 MJ m^-3. In addition, we used several advanced characterization techniques, such as synchrotron radiation FTIR microspectroscopy and synchrotron radiation X-ray diffraction, to reveal the toughening mechanism in such a protein-inorganic hybrid system. We believe our attempt to produce such tough protein-based hybrid fibers by using cheap, abundant and sustainable regenerated silkworm protein and commercially available functionalized carbon nanotubes, with simplified industrial wet-spinning apparatus, may open up a practical way for the industrial production of super-tough fiber materials.

Facile fabrication of robust silk nanofibril films via direct dissolution of silk in CaCl2-formic acid solution

In this study, we report for the first time a novel silk fibroin (SF) nanofibrous films with robust mechanical properties that was fabricated by directly dissolving silk in CaCl2-formic acid solution. CaCl2-FA dissolved silk rapidly at room temperature, and more importantly, it disintegrated silk into nanofibrils instead of separate molecules. The morphology of nanofibrils crucially depended on CaCl2 concentrations, which resulted in different aggregation nanostructure in SF films. The SF film after drawing had maximum elastic modulus, ultimate tensile strength, and strain at break reaching 4 GPa, 106 MPa, and 29%, respectively, in dry state and 206 MPa, 28 MPa, and 188%, respectively, in wet state. Moreover, multiple yielding phenomena and substantially strain-hardening behavior was also observed in the stretched films, indicating the important role played by preparation method in regulating the mechanical properties of SF films. These exceptional and unique mechanical properties were suggested to be caused by preserving silk nanofibril during dissolution and stretching to align these nanofibrils. Furthermore, the SF films exhibit excellent biocompatibility, supporting marrow stromal cells adhesion and proliferation. The film preparation was facile, and the resulting SF films manifested enhanced mechanical properties, unique nanofibrous structures, and good biocompability.

Regeneration of high-quality silk fibroin fiber by wet spinning from CaCl2-formic acid solvent

Silks spun by silkworms and spiders feature outstanding mechanical properties despite being spun under benign conditions. The superior physical properties of silk are closely related to its complicated hierarchical structures constructed from nanoscale building blocks, such as nanocrystals and nanofibrils. Here, we report a novel silk dissolution behavior, which preserved nanofibrils in CaCl2-formic acid solution, that enables spinning of high-quality fibers with a hierarchical structure. This process is characterized by simplicity, high efficiency, low cost, environmental compatibility and large-scale industrialization potential, as well as having utility and potential for the recycling of silk waste and the production of silk-based functional materials.

Effect of degumming ratio on wet spinning and post drawing performance of regenerated silk

Regenerated silk fiber has attracted considerable attention because of its good blood compatibility and cytocompatibility, and the advantages of regenerated fiber, such as control of structure and properties. In this study, wet spun regenerated silk fibers were fabricated by controlling degumming ratio and silk concentration. Rheometry, X-ray diffraction (XRD) and Fourier transform infrared (FTIR) spectroscopy were used to examine wet spinning and post drawing performance of silk. Dope solution viscosity was found to be a key factor determining the continuous fiber formation of silk and 0.07Pa·s was essential for continuous fiber formation. Maximum draw ratio of the as-spun silk fiber was strongly affected by two factors: (1) crystallinity index from FTIR spectroscopy and (2) degumming ratio of silk. XRD of the wet spun silk fibers was not changed by the degumming ratio, silk concentration, and draw ratio. However, the crystallinity indices from FTIR were changed by these factors. Drawing-induced short-range crystallites of the silk were proposed based on FTIR and XRD. These results also show that XRD and FTIR can be used to characterize the micro-structure of silk complementarily because of their different detection characteristics: XRD and FTIR spectroscopy are sensitive to the detection of long- and short-range ordered crystallites of silk, respectively.

Biomimicking the structure of silk fibers via cellulose nanocrystal as β-sheet crystallite

Biomimic silk fibers with refined crystalline structure were produced via incorporating cellulose nanocrystals into silk fibroin matrix to mimic the β-sheet crystallites in natural silk. The fibers exhibit excellent thermal and mechanical properties, attributed to the strong hydrogen bonding interactions between cellulose nanocrystals and silk fibroin as well as cellulose nanocrystal-induced ordered structure.