Slit-surface electrospinning: a novel process developed for high-throughput fabrication of core-sheath fibers

Visualization of porosity and pore size gradients in electrospun scaffolds using laser metrology

We applied a recently developed method, laser metrology, to characterize the influence of collector rotation on porosity gradients of electrospun polycaprolactone (PCL) widely investigated for use in tissue engineering. The prior- and post-sintering dimensions of PCL scaffolds were compared to derive quantitative, spatially-resolved porosity 'maps' from net shrinkage. Deposited on a rotating mandrel (200 RPM), the central region of deposition reaches the highest porosity, ~92%, surrounded by approximately symmetrical decreases to ~89% at the edges. At 1100 RPM, a uniform porosity of ~88-89% is observed. At 2000 RPM, the lowest porosity, ~87%, is found in the middle of the deposition, rebounding to ~89% at the edges. Using a statistical model of random fiber network, we demonstrated that these relatively small changes in porosity values produce disproportionately large variations in pore size. The model predicts an exponential dependence of pore size on porosity when the scaffold is highly porous (e.g., >80%) and, accordingly, the observed porosity variation is associated with dramatic changes in pore size and ability to accommodate cell infiltration. Within the thickest regions most likely to 'bottleneck' cell infiltration, pore size decreases from ~37 to 23 μm (38%) when rotational speeds increased from 200 to 2000 RPM. This trend is corroborated by electron microscopy. While faster rotational speeds ultimately overcome axial alignment induced by cylindrical electric fields associated with the collector geometry, it does so at the cost of eliminating larger pores favoring cell infiltration. This puts the bio-mechanical advantages associated with collector rotation-induced alignment at odds with biological goals. A more significant decrease in pore size from ~54 to ~19 μm (65%), well below the minimum associated with cellular infiltration, is observed from enhanced collector biases. Finally, similar predictions show that sacrificial fiber approaches are inefficient in achieving cell-permissive pore sizes.

Airflow Synergistic Needleless Electrospinning of Instant Noodle-like Curly Nanofibrous Membranes for High-Efficiency Air Filtration

Particulate matter (PM) pollution has become a serious environmental concern. Nanofibrous filters are widely reported to remove PM from polluted air. Herein, efficient and lightweight PM air filters are presented using airflow synergistic needleless electrospinning composed of auxiliary fields such as an airflow field and a secondary inductive electric field. Compared to needleless electrospinning with other spinnerets, it significantly improves productivity, fiber diameter, and porosity of fibrous air filters. The instant noodle-like nanofiber structure can also be controlled by adjusting the airflow velocity. These air filters exhibit high (2.5 μm particulate matter) PM_2.5 removal efficiency (99.9%) and high (0.3 μm particulate matter) PM_0.3 removal efficiency (99.1%), low pressure drop (56 Pa for PM_2.5 and 78 Pa for PM_0.3 ), and large dust holding capacitance (the maximum value is 168 g m^-2 for PM_2.5 , while 102 g m^-2 for PM_0.3 ). Meanwhile, the proposed PM filters are also tested suitable and stable to other polluted air filtrations such as cigarette smoke and sawdust. The large-scale synthesis of such an attractive nanofiber structure presents the great potential of high-performance filtration/separation materials.

Scaffolding Biomaterials for 3D Cultivated Meat: Prospects and Challenges

Cultivating meat from stem cells rather than by raising animals is a promising solution to concerns about the negative externalities of meat production. For cultivated meat to fully mimic conventional meat's organoleptic and nutritional properties, innovations in scaffolding technology are required. Many scaffolding technologies are already developed for use in biomedical tissue engineering. However, cultivated meat production comes with a unique set of constraints related to the scale and cost of production as well as the necessary attributes of the final product, such as texture and food safety. This review discusses the properties of vertebrate skeletal muscle that will need to be replicated in a successful product and the current state of scaffolding innovation within the cultivated meat industry, highlighting promising scaffold materials and techniques that can be applied to cultivated meat development. Recommendations are provided for future research into scaffolds capable of supporting the growth of high-quality meat while minimizing production costs. Although the development of appropriate scaffolds for cultivated meat is challenging, it is also tractable and provides novel opportunities to customize meat properties.

Electrospun Biomaterials’ Applications and Processing

One of the largest fields of application of electrospun materials is the biomedical field, including development of scaffolds for tissue engineering, drug delivery and wound healing. Electrospinning appears as a promising technique in terms of scaffolds composition and architecture, which is the main aspect of this review paper, with a special attention to natural polymers including collagen, fibrinogen, silk fibroin, chitosan, chitin etc. Thanks to the adaptability of the electrospinning process, versatile hybrid, custom tailored structure scaffolds have been reported. The same is achieved due to the vast biomaterials’ processability as well as modifications of the basic electrospinning set-up and its combination with other techniques, simultaneously or by post-processing.

A Novel Profiled Multi-Pin Electrospinning System for Nanofiber Production and Encapsulation of Nanoparticles into Nanofibers

Electrospinning with various machine configurations is being used to produce polymer nanofibers with different rates of output. The use of polymers with high viscosity and the encapsulation of nanoparticles for achieving functionalities are some of the limitations of the existing methods. A profiled multi-pin electrospinning (PMES) setup is demonstrated in this work that overcomes the limitations in the needle and needleless electrospinning like needle clogging, particle settling, and uncontrolled/uneven Taylor cone formation, the requirement of very high voltage and uncontrolled distribution of nanoparticles in nanofibers. The key feature of the current setup is the use of profiled pin arrangement that aids in the formation of spherical shape polymer droplet and hence ensures uniform Taylor cone formation throughout the fiber production process. With a 10 wt% of Polyvinyl Alcohol (PVA) polymer solution and at an applied voltage of 30 kV, the production rate was observed as 1.690 g/h and average fiber diameter obtained was 160.5 ± 48.9 nm for PVA and 124.9 ± 49.8 nm for Cellulose acetate (CA) respectively. Moreover, the setup also provides the added advantage of using high viscosity polymer solutions in electrospinning. This approach is expected to increase the range of multifunctional electrospun nanofiber applications.

An Overview of Chitosan Nanofibers and their Applications in the Drug Delivery Process

Chitosan is a polycationic natural polymer which is abundant in nature. Chitosan has gained much attention as natural polymer in the biomedical field. The up to date drug delivery as well as the nanotechnology in controlled release of drugs from chitosan nanofibers are focused in this review. Electrospinning is one of the most established and widely used techniques for preparing nanofibers. This method is versatile and efficient for the production of continuous nanofibers. The chitosan-based nanofibers are emerging materials in the arena of biomaterials. Recent studies revealed that various drugs such as antibiotics, chemotherapeutic agents, proteins and anti-inflammatory analgesic drugs were successfully loaded onto electrospun nanofibers. Chitosan nanofibers have several outstanding properties for different significant pharmaceutical applications such as wound dressing, tissue engineering, enzyme immobilization, and drug delivery systems. This review highlights different issues of chitosan nanofibers in drug delivery applications, starting from the preparation of chitosan nanofibers, followed by giving an idea about the biocompatibility and degradation of chitosan nanofibers, then describing how to load the drug into the nanofibers. Finally, the major applications of chitosan nanofibers in drug delivery systems.

Coaxial Electrospinning Formation of Complex Polymer Fibers and their Applications

The formation of fibers by electrospinning has experienced explosive growth in the past decade, recently reaching 4,000 publications and 1,500 patents per year. This impressive growth of interest is due to the ability to form fibers with a variety of materials, which lend themselves to a large and rapidly expanding set of applications. In particular, coaxial electrospinning, which forms fibers with multiple core-sheath layers from different materials in a single step, enables the combination of properties in a single fiber that are not found in nature in a single material. This article is a detailed review of coaxial electrospinning: basic mechanisms, early history and current status, and an in-depth discussion of various applications (biomedical, environmental, sensors, energy, catalysis, textiles). We aim to provide readers who are currently involved in certain aspects of coaxial electrospinning research an appreciation of other applications and of current results.

Recent Progress in Coaxial Electrospinning: New Parameters, Various Structures, and Wide Applications

Electrospinning, a common method for synthesizing 1D nanostructures, has contributed to developments in the electrical, electrochemical, biomedical, and environmental fields. Recently, a coaxial electrospinning process has been used to fabricate new nanostructures with advanced performance, but intricate and delicate process conditions hinder reproducibility and mass production. Herein, recent progress in new emerging parameters for successful coaxial electrospinning, and the various nanostructures and critical application areas resulting from these activities. Relationships between the new parameters and final product characteristics are described, new possibilities for nanostructures achievable via coaxial electrospinning are identified, and new research directions with a view to future applications are suggested.

Influence of Working Temperature on The Formation of Electrospun Polymer Nanofibers

Temperature is an important parameter during electrospinning, and virtually, all solution electrospinning processes are conducted at ambient temperature. Nanofiber diameters presumably decrease with the elevation of working fluid temperature. The present study investigated the influence of temperature variations on the formation of polymeric nanofibers during single-fluid electrospinning. The surface tension and viscosity of the fluid decreased with increasing working temperature, which led to the formation of high-quality nanofibers. However, the increase in temperature accelerated the evaporation of the solvent and thus terminated the drawing processes prematurely. A balance can be found between the positive and negative influences of temperature elevation. With polyacrylonitrile (PAN, with N,N-dimethylacetamide as the solvent) and polyvinylpyrrolidone (PVP, with ethanol as the solvent) as the polymeric models, relationships between the working temperature (T, K) and nanofiber diameter (D, nm) were established, with D = 12598.6 - 72.9T + 0.11T ² (R = 0.9988) for PAN fibers and D = 107003.4 - 682.4T + 1.1T ² (R = 0.9997) for PVP nanofibers. Given the fact that numerous polymers are sensitive to temperature and numerous functional ingredients exhibit temperature-dependent solubility, the present work serves as a valuable reference for creating novel functional nanoproducts by using the elevated temperature electrospinning process.

Hollow Polycaprolactone Microspheres with/without a Single Surface Hole by Co-Electrospraying

We describe the co-electrospraying of hollow microspheres from a polycaprolactone (PCL) shell solution and various core solutions including water, cyclohexane, poly(ethylene oxide) (PEO), and polyethylene glycol (PEG), using different collectors. The morphologies of the resultant microspheres were characterized by scanning electron microscopy (SEM), confocal microscopy, and nano-X-ray computed tomography (nano-XCT). The core/shell solution miscibility played an important role in the co-electrospraying process and the formation of microsphere structures. Spherical particles were more likely to be produced from miscible combinations of core/shell solutions than from immiscible ones. Hollow PCL microspheres with a single hole in their surfaces were produced when an ethanol bath was used as the collector. The mechanism by which the core/shell structure is transformed into single-hole hollow microspheres is proposed to be primarily based on the evaporation through the shell and extraction by ethanol of the core solution and is described in detail. Additionally, we present a 3D macroscopic tubular structure composed of hollow PCL microspheres, directly assembled on a copper wire collector during co-electrospraying. SEM and nano-XCT confirm that microspheres in the 3D bulk structure remain hollow.

Preparation and characterization of polycaprolactone microspheres by electrospraying

The ability to reproducibly produce and effectively collect electrosprayed polymeric microspheres with controlled morphology and size in bulk form is challenging. In this study, microparticles were produced by electrospraying polycaprolactone (PCL) of various molecular weights and solution concentrations in chloroform, and by collecting materials on different substrates. The resultant PCL microparticles were characterized by optical and electron microscopy to investigate the effect of molecular weight, solution concentration, applied voltage, working distance, and flow rate on their morphology and size. The work demonstrates the key role of a moderate molecular weight and/or solution concentration in the formation of spherical PCL particles via an electrospraying process. Increasing the applied voltage was found to produce smaller and more uniform PCL microparticles. There was a relatively low increase in the particle average size with an increase in the working distance and flow rate. Four types of substrates were adopted to collect electrosprayed PCL particles: a glass slide, aluminium foil, liquid bath, and copper wire. Unlike 2D bulk structures collected on the other substrates, a 3D tubular structure of microspheres was formed on the copper wire which could find application in the construction of 3D tumor mimics.

In pursuit of functional electrospun materials for clinical applications in humans

Electrospinning is a simple, low-cost and versatile approach to fabricate multifunctional materials useful in drug delivery and tissue engineering applications. Despite its emergence into other manufacturing sectors, electrospinning has not yet made a transformative impact in the clinic with a pharmaceutical product for use in humans. Why is this the current state of electrospun materials in biomedicine? Is it because electrospun materials are not yet capable of overcoming the biological safety and efficacy challenges needed in pharmaceutical products? Or, is it that technological advances in the electrospinning process are needed? This review investigates the current state of electrospun materials in medicine to identify both scientific and technological gaps that may limit clinical translation.

Coaxially electrospun fiber-based microbicides facilitate broadly tunable release of maraviroc

Electrospun fibers show potential as a topical delivery system for vaginal microbicides. Previous reports have demonstrated delivery of anti-HIV and anti-STI (sexually transmitted infection) agents from fibers formulated using hydrophilic, hydrophobic, or pH-responsive polymers that result in rapid, prolonged, or stimuli-responsive release, respectively. However, coaxial electrospun fibers have yet to be evaluated as a highly tunable microbicide delivery vehicle. In this research, we explored the opportunities and limitations of a model coaxial electrospun fiber system to provide broad and tunable release rates for the HIV entry inhibitor maraviroc. Specifically, we prepared ethyl cellulose (EC)-shell and polyvinylpyrrolidone (PVP)-core fibers that were capable of releasing actives over a range of hours to several days. We further demonstrated simple and effective methods for combining core-shell fibers with rapid-release formulations to provide combined instantaneous and sustained maraviroc release. In addition, we investigated the effect of varying release media on maraviroc release from core-shell fibers, and found that release was strongly influenced by media surface tension and drug ionization. Finally, in vitro cell culture studies show that our fiber formulations were not cytotoxic and that electrospun maraviroc maintained similar antiviral activity compared to neat maraviroc.