Effective AC needleless and collectorless electrospinning for yarn production

Triple-layered encapsulation of sensitive biomolecules into poly (ε-caprolactone) nanofibers using AC electrospraying

The incorporation of sensitive bioactive substances such as proteins or DNA into nanofibers poses a significant problem due to the toxicity of most organic solvents. The main idea of this study is to use alternating current electrospraying to create a suspension consisting of polyvinyl alcohol (PVA) capsules containing a bioactive substance dispersed in a solvent system suitable for a water-insoluble biocompatible polymer. In this suspension consisting of PVA capsules and a chloroform/ethanol mixture, poly (ε-caprolactone) (PCL) was dissolved and spun by needle-free electrospinning. The result is a fibrous PCL structure in which PVA capsules containing the bioactive agent are integrated. The PVA capsules protect the bioactive substance from the organic solvents needed to dissolve the PCL. To verify the efficacy of the capsules' protection against chloroform, the green fluorescent protein was first encapsulated into the nanofibers, followed by horseradish peroxidase. Both molecules were shown to retain their bioactivity within the nanofibers.

Alternating Current Electrospinning of Polycaprolactone/Chitosan Nanofibers for Wound Healing Applications

Traditional wound dressings have not been able to satisfy the needs of the regenerative medicine biomedical area. With the aim of improving tissue regeneration, nanofiber-based wound dressings fabricated by electrospinning (ES) processes have emerged as a powerful approach. Nowadays, nanofiber-based bioactive dressings are mainly developed with a combination of natural and synthetic polymers, such as polycaprolactone (PCL) and chitosan (CHI). Accordingly, herein, PCL/CHI nanofibers have been developed with varying PCL:CHI weight ratios (9:1, 8:2 and 7:3) or CHI viscosities (20, 100 and 600 mPa·s) using a novel alternating current ES (ACES) process. Such nanofibers were thoroughly characterized by determining physicochemical and nanomechanical properties, along with wettability, absorption capacity and hydrolytic plus enzymatic stability. Furthermore, PCL/CHI nanofiber biological safety was validated in terms of cytocompatibility and hemocompatibility (hemolysis < 2%), in addition to a notable antibacterial performance (bacterial reductions of 99.90% for S. aureus and 99.91% for P. aeruginosa). Lastly, the enhanced wound healing activity of PCL/CHI nanofibers was confirmed thanks to their ability to remarkably promote cell proliferation, which make them ideal candidates for long-term applications such as wound dressings.

Optimal delivery of poorly soluble drugs using electrospun nanofiber technology: Challenges, state of the art, and future directions

Poor aqueous solubility of both, existing drug molecules and those which are currently in the developmental stage, have posed a great challenge to pharmaceutical scientists because they often exhibit poor dissolution behavior and subsequent poor and erratic bioavailability. This has triggered extensive research to explore nanotechnology-based technology platforms for possible rescue. Recently, nanofibers have been exploited widely for diverse biomedical applications including for drug delivery. Electrospun nanofibers are capable of preserving the homogeneously loaded therapeutic agents in amorphous state potentialy impairing devitrification. The present review aims at providing an overview of the various key factors that affect the electrospinning process and characteristics of the nanofibers while fabrication of drug loaded nanofibers for poorly soluble drug candidates. The review explores various methodological advancements in the electrospinning process and set-ups for production scale-up. The various types of electrospun nanofibers (like simple matrix, core-sheath, Janus, and inclusion complex nanofibers) that have been exploited for the delivery of poorly soluble drugs are also critically assessed. This article is categorized under: Therapeutic Approaches and Drug Discovery > Emerging Technologies.

Production of Modified Composite Nanofiber Yarns with Functional Particles

The study focused on the production of modified composite nanofiber yarns with fine functional particles. A device that incorporates fine functional particles into a nanofiber yarn wrapper was specially developed, which ensures the continuous production of modified yarn. It was demonstrated during the study that the specially designed equipment could be used effectively for incorporating fine functional particles into the nanofiber packaging, thus creating a unique yarn with high application potential. The use of particles with dimensions of just tens of micrometers results in the uneven flow of particles inside the chamber and the uneven supply of particles to the composite yarn. The study also determined that the number of particles incorporated into the composite yarn is affected by the particle concentration and the variation of the vortex velocity ratios in the chamber. During testing, it was also found that the nanofiber sheet of the composite yarn improves the mechanical properties of the produced yarn. In addition, the study included the semi-industrial production of a composite filter candle, which can be used for the treatment of fluids, especially air and water.

Modification and Functionalization of Fibers Formed by Electrospinning: A Review

The development of new materials with specific functionalities for certain applications has been increasing with the advent of nanotechnology. A technique widely used for this purpose is electrospinning, because control of several parameters involved in the process can yield nanoscale fibers. In addition to the production of innovative and small-scale materials, through structural, chemical, physical, and biological modifications in the fibers produced in electrospinning, it is possible to obtain specific properties for a given application. Thus, the produced fibers can serve different purposes, such as in the areas of sensors, catalysis, and environmental and medical fields. Given this context, this article presents a review of the electrospinning technique, addressing the parameters that influence the properties of the fibers formed and some techniques used to modify them as specific treatments that can be conducted during or after electrospinning. In situ addition of nanoparticles, changes in the configuration of the metallic collector, use of alternating current, electret fibers, core/shell method, coating, electrospray-coating, plasma, reinforcing composite materials, and thermal treatments are some of the examples addressed in this work. Therefore, this work contributes to a better comprehension of some of the techniques mentioned in the literature so far.

Electrospun nanofibrous membrane for biomedical application

Electrospinning is a simple, cost-effective, flexible, and feasible continuous micro-nano polymer fiber preparation technology that has attracted extensive scientific and industrial interest over the past few decades, owing to its versatility and ability to manufacture highly tunable nanofiber networks. Nanofiber membrane materials prepared using electrospinning have excellent properties suitable for biomedical applications, such as a high specific surface area, strong plasticity, and the ability to manipulate their nanofiber components to obtain the desired properties and functions. With the increasing popularity of nanomaterials in this century, electrospun nanofiber membranes are gradually becoming widely used in various medical fields. Here, the research progress of electrospun nanofiber membrane materials is reviewed, including the basic electrospinning process and the development of the materials as well as their biomedical applications. The main purpose of this review is to discuss the latest research progress on electrospun nanofiber membrane materials and the various new electrospinning technologies that have emerged in recent years for various applications in the medical field. The application of electrospun nanofiber membrane materials in recent years in tissue engineering, wound dressing, cancer diagnosis and treatment, medical protective equipment, and other fields is the main topic of discussion in this review. Finally, the development of electrospun nanofiber membrane materials in the biomedical field is systematically summarized and prospects are discussed. In general, electrospinning has profound prospects in biomedical applications, as it is a practical and flexible technology used for the fabrication of microfibers and nanofibers.

This review summarizes recent research on the application of electrospun nanofiber membranes as tissue engineering materials for the cardiovascular system, motor system, nervous system, and other clinical aspects.

Research on the application of electrospun nanofiber membrane materials as protective products is discussed in the context of the current epidemic situation.

Examples and analyses of recent popular applications in tissue engineering, wound dressing, protective products, and cancer sensors are presented.

Preparation of a Hydrogel Nanofiber Wound Dressing

The study addressed the production of a hydrogel nanofiber skin cover and included the fabrication of hydrogel nanofibers from a blend of polyvinyl alcohol and alginate. The resulting fibrous layer was then crosslinked with glutaraldehyde, and, after 4 h of crosslinking, although the gelling component, i.e., the alginate, crosslinked, the polyvinyl alcohol failed to do so. The experiment included the comparison of the strength and ductility of the layers before and after crosslinking. It was determined that the fibrous layer following crosslinking evinced enhanced mechanical properties, which acted to facilitate the handling of the material during its application. The subsequent testing procedure proved that the fibrous layer was not cytotoxic. The study further led to the production of a modified hydrogel nanofiber layer that combined polyvinyl alcohol with alginate and albumin. The investigation of the fibrous layers produced determined that following contact with water the polyvinyl alcohol dissolved leading to the release of the albumin accompanied by the swelling of the alginate and the formation of a hydrogel.

The Optimization of Alternating Current Electrospun PA 6 Solutions Using a Visual Analysis System

The electrospinning process that produces fine nanofibrous materials have a major disadvantage in the area of productivity. However, alternating current (AC) electrospinning might help to solve the problem via the modification of high voltage signal. The aforementioned productivity aspect can be observed via a camera system that focuses on the jet creation area and that measures the average lifespan. The paper describes the optimization of polyamide 6 (PA 6) solutions and demonstrates the change in the behavior of the process following the addition of a minor dose of oxoacid. This addition served to convert the previously unspinnable (using AC) solution to a high-quality electrospinning solution. The visual analysis of the AC electrospinning of polymeric solutions using a high-speed camera and a programmable power source was chosen as the method for the evaluation of the quality of the process. The solutions were exposed to high voltage applying two types of AC signal, i.e., the sine wave and the step change. All the recordings presented in the paper contained two sets of data: firstly, camera recordings that showed the visual expression of electrospinning and, secondly, signal recordings that provided information on the data position in the signal function.

Electrospinning of Nanofibrous Membrane and Its Applications in Air Filtration: A Review

Air pollution caused by particulate matter and toxic gases is violating individual’s health and safety. Nanofibrous membrane, being a reliable filter medium for particulate matter, has been extensively studied and applied in the field of air purification. Among the different fabrication approaches of nanofibrous membrane, electrospinning is considered as the most favorable and effective due to its advantages of controllable process, high production efficiency, and low cost. The electrospun membranes, made of different materials and unique structures, exhibit good PM2.5 filtration performance and multi-functions, and are used as masks and filters against PM2.5. This review presents a brief overview of electrospinning techniques, different structures of electrospun nanofibrous membranes, unique characteristics and functions of the fabricated membranes, and summarization of the outdoor and indoor applications in PM filtration.

Preparation of a Composite Scaffold from Polycaprolactone and Hydroxyapatite Particles by Means of Alternating Current Electrospinning

This research involved the production of polycaprolactone fiber layers via the alternating current electrospinning method. To construct the micro/nanofiber scaffold, mixtures of two molecular weight solutions, M _n 45 000 and M _n 80 000, were spun in differing proportions in a solvent system containing acetic acid, formic acid, and acetone in a ratio of 1:1:1. The composite fiber materials with hydroxyapatite particles were prepared from a solution that combined the different molecular weight solutions at a ratio of 1:3. The study resulted in the preparation of fiber layers containing 0, 5, 10, and 15% (wt) hydroxyapatite particles from the dry mass of the polycaprolactone. The strength, wettability, and surface energy of the composite materials were examined, and the results demonstrated that hydroxyapatite affects the fiber diameters, strength, and surface energy and, thus, the wettability of the fiber layers. The fibrous layers produced were further tested for cytotoxicity and cell viability and proliferation. The results obtained thus strongly indicate that the resulting bulky micro/nanofiber layers are suitable for further testing with a view to their eventual application in the field of bone tissue engineering.

Frequency and waveform dependence of alternating current electrospinning and their uses for drug dissolution enhancement

The effect of different frequencies and waveforms was investigated for the first time on alternating current electrospinning (ACES). PVPVA64, a polyvinylpyrrolidone-vinyl acetate copolymer was selected for the experiments as an important matrix for amorphous solid dispersions but never processed with ACES. It has been proved that ACES could be operated in a wide range of frequencies (40-250 Hz) and using different waveforms (sinusoidal, square, triangle, saw tooth) without significant changes in fiber morphology. Nevertheless, deterioration of the fiber formation process could be also observed especially at high frequencies. The developed PVPVA64-based fibers containing small amounts of additives (polyethylene oxide (PEO) and sodium dodecyl sulfate (SDS)) served as an excellent carrier for spironolactone (SPIR), a poorly soluble antihypertensive drug. As a result of the amorphously dispersed SPIR and the large surface area of the AC electrospun fibers immediate drug release could be achieved.

A Mini-Review: Needleless Electrospinning of Nanofibers for Pharmaceutical and Biomedical Applications

Electrospinning (ES) is a convenient and versatile method for the fabrication of nanofibers and has been utilized in many fields including pharmaceutical and biomedical applications. Conventional ES uses a needle spinneret for the generation of nanofibers and is associated with many limitations and drawbacks (i.e., needle clogging, limited production capacity, and low yield). Needleless electrospinning (NLES) has been proposed to overcome these problems. Within the last two decades (2004–2020), many research articles have been published reporting the use of NLES for the fabrication of polymeric nanofibers intended for drug delivery and biomedical tissue engineering applications. The objective of the present mini-review article is to elucidate the potential of NLES for designing such novel nanofibrous drug delivery systems and tissue engineering constructs. This paper also gives an overview of the key NLES approaches, including the most recently introduced NLES method: ultrasound-enhanced electrospinning (USES). The technologies underlying NLES systems and an evaluation of electrospun nanofibers are presented. Even though NLES is a promising approach for the industrial production of nanofibers, it is a multivariate process, and more research work is needed to elucidate its full potential and limitations.

ac Bubble Electrospinning Technology for Preparation of Nanofibrous Mats

This study deals with a new combination of alternating current (ac) electrospinning and bubble electrospinning. Research devoted to the combination of these two methods for the preparation of nanofibrous and microfibrous mats has been carried out. The design, construction, and description of bubble electrospinning are described in this article. The final morphologies of the fibrous layers produced by these methods have been compared with other well-known electrospinning methods. The bubble electrospinning and ac electrospinning aspire to become new technologies that could be utilized in various technical areas and tissue-engineering applications.

Nanofibrous TiO2 produced using alternating field electrospinning of titanium alkoxide precursors: crystallization and phase development

High-yield, free-surface alternating field electrospinning (AFES) was effectively used in the fabrication of titanium oxide nanofibrous materials from the precursors based on titanium alkoxide and a blend of polyvinylpyrrolidone and hydroxypropyl cellulose. The alkoxide/polymer mass ratio in the precursor solution has significant effects on the precursor fiber production rate as well as the structure of resulting TiO2 nanofibers after thermal processing of precursor fibers at temperatures from 500 to 1000 °C. Within the range of tested process parameters, the best fiber production rate of ∼5.2 g h-1 was achieved, in terms of the mass of crystallized TiO2 nanofibers, with the precursor that corresponded to 1.5 : 1 TiO2/polymer mass ratio. TiO2 nanofibers produced by calcination at 500 °C for 3 h had 100-500 nm diameters and were composed of anatase (20-25 nm crystallite size) with rutile content 0.1-6.0 mol%, depending on the precursor composition. A considerable amount of anatase phase (up to 80 mol%) can be retained after thermal processing of TiO2 nanofibers at 750 °C for 3 h. A nanofibrous material composed of smooth and long, predominantly monocrystalline rutile, fibrous segments was produced at 1000 °C from the precursor with 2.5 : 1 TiO2/polymer mass ratio.

Experimental fortification of intestinal anastomoses with nanofibrous materials in a large animal model

Anastomotic leakage is a severe complication in gastrointestinal surgery. It is often a reason for reoperation together with intestinal passage blockage due to formation of peritoneal adhesions. Different materials as local prevention of these complications have been studied, none of which are nowadays routinely used in clinical practice. Nanofabrics created proved to promote healing with their structure similar to extracellular matrix. We decided to study their impact on anastomotic healing and formation of peritoneal adhesions. We performed an experiment on 24 piglets. We constructed 3 hand sutured end-to-end anastomoses on the small intestine of each pig. We covered the anastomoses with a sheet of polycaprolactone nanomaterial in the first experimental group, with a sheet of copolymer of polylactic acid with polycaprolactone in the second one and no fortifying material was used in the Control group. The animals were sacrificed after 3 weeks of observation. Clinical, biochemical and macroscopic signs of anastomotic leakage or intestinal obstruction were monitored, the quality of the scar tissue was assessed histologically, and a newly developed scoring system was employed to evaluate the presence of adhesions. The material is easy to manipulate with. There was no mortality or major morbidity in our groups. No statistical difference was found inbetween the groups in the matter of level of peritoneal adhesions or the quality of the anastomoses. We created a new adhesion scoring system. The material appears to be safe however needs to be studied further to prove its' positive effects.

Polyvinyl Butyral (PVB) Nanofiber/Nanoparticle-Covered Yarns for Antibacterial Textile Surfaces

In this study, nanoparticle-incorporated nanofiber-covered yarns were prepared using a custom-made needle-free electrospinning system. The ultimate goal of this work was to prepare functional nanofibrous surfaces with antibacterial properties and realize high-speed production. As antibacterial agents, we used various amounts of copper oxide (CuO) and vanadium (V) oxide (V₂O₅) nanoparticles (NPs). Three yarn preparation speeds (100 m/min, 150 m/min, and 200 m/min) were used for the nanofiber-covered yarn. The results indicate a relationship between the yarn speed, quantity of NPs, and antibacterial efficiency of the material. We found a higher yarn speed to be associated with a lower reduction in bacteria. NP-loaded nanofiber yarns were proven to have excellent antibacterial properties against Gram-negative Escherichia coli (E. coli). CuO exhibited a greater inhibition and bactericidal effect against E. coli than V₂O₅. In brief, the studied samples are good candidates for use in antibacterial textile surface applications, such as wastewater filtration. As greater attention is being drawn to this field, this work provides new insights regarding the antibacterial textile surfaces of nanofiber-covered yarns.

Corona alternating current electrospinning: A combined approach for increasing the productivity of electrospinning

Corona alternating current electrospinning (C-ACES), a scaled-up productivity electrospinning method was developed by combining the intense forces of the alternating electrostatic field and a sharp-edged spinneret design with increased free surface. C-ACES reached two orders of magnitude higher productivity (up to 1200 mL/h) than the classical single needle direct current electrospinning (DCES) without any alteration of fiber properties. Polyvinylpyrrolidone K90 (PVPK90), a water soluble high molecular weight nonionic polymer was processed for the first time with single needle alternating current electrospinning (ACES) and C-ACES in order to prepare fast dissolving amorphous solid dispersions of spironolactone (SPIR), a poorly water-soluble antihypertensive model drug. The limited spinnability of PVPK90 with AC high voltage could only be resolved by optimizing the solution conductivity with organophilic salts such as sodium dodecyl sulfate (SDS) demonstrating the importance of conductivity during ACES. The effects of varied solution properties (composition and conductivity) and scaling-up were investigated by SEM imaging. Solid state analyses revealed that SPIR was dispersed in an amorphous form in the fibrous mats. In vitro dissolution tests showed ultrafast drug release in case of the amorphous formulations even when prepared with scaled-up C-ACES. Besides the enhancement of conductivity SDS also prevents SPIR from precipitation from the dissolution media due to its solubilization ability.

Fabrication of dual-functional composite yarns with a nanofibrous envelope using high throughput AC needleless and collectorless electrospinning

Nanotechnologies allow the production of yarns containing nanofibres for use in composites, membranes and biomedical materials. Composite yarns with a conventional thread core for mechanical strength and a nanofibrous envelope for functionality, e.g. biological, catalytic, have many advantages. Until now, the production of such yarns has been technologically difficult. Here, we show an approach to composite yarn production whereby a plume of nanofibers generated by high throughput AC needleless and collectorless electrospinning is wound around a classic thread. In the resulting yarn, nanofibres can form up to 80% of its weight. Our yarn production speed was 10 m/min; testing showed this can be increased to 60 m/min. After the yarn was embedded into knitwear, scanning electron microscope images revealed an intact nanofibrous envelope of the composite yarn. Our results indicate that this production method could lead to the widespread production and use of composite nanofibrous yarns on an industrial scale.

Novel Alternating Current Electrospinning of Hydroxypropylmethylcellulose Acetate Succinate (HPMCAS) Nanofibers for Dissolution Enhancement: The Importance of Solution Conductivity

Novel, high-yield alternating current electrospinning (ACES) and direct current electrospinning methods were investigated to prepare high-quality hydroxypropylmethylcellulose acetate succinate (HPMCAS) fibers for the dissolution enhancement of poorly soluble spironolactone. Although HPMCAS is of great pharmaceutical importance as a carrier of marketed solid dispersion-based products, it was found to be unprocessable using electrospinning. Addition of small amounts of polyethylene oxide as aid polymer provided smooth fibers with direct current electrospinning but strongly beaded products with ACES. Solution characteristics were thus modified by introducing further excipients. In the presence of sodium dodecyl sulfate, high-quality, HPMCAS-based fibers were obtained even at higher throughput rates of ACES owing to the change in conductivity (rather than surface tension). Replacement of sodium dodecyl sulfate with non-surface-active salts (calcium chloride and ammonium acetate) maintained the fine quality of nanofibers, confirming the importance of conductivity in ACES process. The HPMCAS-based fibers contained spironolactone in an amorphous form according to differential scanning calorimetry and X-ray powder diffraction. In vitro dissolution tests revealed fast drug release rates depending on the salt used to adjust conductivity. The presented results signify that ACES can be a prospective process for high-scale production of fibrous solid dispersions in which conductivity of solution has a fundamental role.

Electrospun Scaffolds for Corneal Tissue Engineering: A Review

Corneal diseases constitute the second leading cause of vision loss and affect more than 10 million people globally. As there is a severe shortage of fresh donated corneas and an unknown risk of immune rejection with traditional heterografts, it is very important and urgent to construct a corneal equivalent to replace pathologic corneal tissue. Corneal tissue engineering has emerged as a practical strategy to develop corneal tissue substitutes, and the design of a scaffold with mechanical properties and transparency similar to that of natural cornea is paramount for the regeneration of corneal tissues. Nanofibrous scaffolds produced by electrospinning have high surface area-to-volume ratios and porosity that simulate the structure of protein fibers in native extra cellular matrix (ECM). The versatilities of electrospinning of polymer components, fiber structures, and functionalization have made the fabrication of nanofibrous scaffolds with suitable mechanical strength, transparency and biological properties for corneal tissue engineering feasible. In this paper, we review the recent developments of electrospun scaffolds for engineering corneal tissues, mainly including electrospun materials (single and blended polymers), fiber structures (isotropic or anisotropic), functionalization (improved mechanical properties and transparency), applications (corneal cell survival, maintenance of phenotype and formation of corneal tissue) and future development perspectives.

Teslaphoresis of Carbon Nanotubes

This paper introduces Teslaphoresis, the directed motion and self-assembly of matter by a Tesla coil, and studies this electrokinetic phenomenon using single-walled carbon nanotubes (CNTs). Conventional directed self-assembly of matter using electric fields has been restricted to small scale structures, but with Teslaphoresis, we exceed this limitation by using the Tesla coil's antenna to create a gradient high-voltage force field that projects into free space. CNTs placed within the Teslaphoretic (TEP) field polarize and self-assemble into wires that span from the nanoscale to the macroscale, the longest thus far being 15 cm. We show that the TEP field not only directs the self-assembly of long nanotube wires at remote distances (>30 cm) but can also wirelessly power nanotube-based LED circuits. Furthermore, individualized CNTs self-organize to form long parallel arrays with high fidelity alignment to the TEP field. Thus, Teslaphoresis is effective for directed self-assembly from the bottom-up to the macroscale.

Highly-twisted, continuous nanofibre yarns prepared by a hybrid needle-needleless electrospinning technique

A hybrid needle-needleless electrospinning technique has been developed to directly convert polymer solution into a highly-twisted, continuous nanofibre yarn.

Ribbon-like and spontaneously folded structures of tungsten oxide nanofibers fabricated via electrospinning

Electrospinning of sub-100 nm thick WO₃ ribbon-like nanofibers and their periodically folded patterns is reported for the first time.

Protrusion of the Rod Electrode in the Electrospinning Process

The paper focuses on the influence of the protrusion of the rod electrode on critical voltage in the DC electrospinning process. On the testing and industrial DC electrospinning devices, electrodes of any kind are extended towards the counter electrode. This provides the maximal, that is, supercritical, electric field intensity on the spinning-electrode orifice that is found to be higher than on the other supplementary parts. The principal study and experiments with basic apparatus were carried out and presented by Taylor in 1966. This study is focused on the arrangement closely related to the design of the real electrospinning device with respect to the safety and technological aspects. Results of the carried out experiments of the rod spinning-electrode are compared with the electrostatic simulation and analytical calculation. The presented effect of the electrode protrusion on the potential difference and the critical field strength introduces valuable information for the designers of electrospinning machines as well as for the setting up of the optimal technological parameters for producing modern nonwoven textile products.