Fiber Alignment Research Articles

Confinement Modulates Axial Patterning in Regenerating Hydra

The establishment of the body plan is a major step in animal morphogenesis. The role of mechanical forces and feedback in patterning the body plan remains unclear. Here we explore this question by studying regenerating Hydra tissues confined in narrow cylindrical channels, which constrain their morphology. We find that frustration between the orientation of the channel and the inherited axis in the regenerating tissues can lead to the formation of a multiaxial body plan. The morphological outcome is directly related to the pattern of nematic topological defects that emerges in the organization of the supracellular actomyosin fibers. When the inherited axis, which can be read out from the initial alignment of the supracellular fibers in the confined spheroid, is parallel to the channel's axis, the tissue regenerates normally into animals with a single body axis aligned with the channel. However, regenerating spheroids that are confined in a frustrated perpendicular configuration often develop excess defects (including negatively charged −1/2 defects) and regenerate into multiaxial morphologies. The influence of mechanical constraints on the regenerated body plan argues against an axial patterning mechanism that is based solely on inherited gradients of biochemical morphogens. We further show that the dependence of the regeneration outcomes on the initial tissue orientation can be recapitulated by a biophysical model, which considers the coupled dynamics of the nematic organization of the actomyosin fibers and a morphogen concentration field, incorporating a mechanochemical feedback loop involving strain-dependent morphogen production at defect sites. Published by the American Physical Society 2024

Programmable and flexible wood-based origami electronics

Natural polymer substrates are gaining attention as substitutes for plastic substrates in electronics, aiming to combine high performance, intricate shape deformation, and environmental sustainability. Herein, natural wood veneer is converted into a transparent wood film (TWF) substrate. The combination of 3D printing and origami technique is established to create programmable wood-based origami electronics, which exhibit superior flexibility with high tensile strength (393 MPa) due to the highly aligned cellulose fibers and the formation of numerous intermolecular hydrogen bonds between them. Moreover, the flexible TWF electronics exhibit editable multiplexed configurations and maintain stable conductivity. This is attributed to the strong adhesion between the cellulose-based ink and TWF substrate by non-covalent bonds. Benefiting from its anisotropic structure, the programmability of TWF electronics is achieved through sequentially folding into predesigned shapes. This design not only promotes environmental sustainability but also introduces its customizable shapes with potential applications in sensors, microfluidics, and wearable electronics.

Electrospinning Aligned SF/Magnetic Nanoparticles-Blend Nanofiber Scaffolds for Inducing Skeletal Myoblast Alignment and Differentiation.

In the realm of skeletal muscle tissue engineering, anisotropic materials that emulate natural tissues show substantial promise. Electrospun scaffolds, mimicking the fibrillar structure of the extracellular matrix, are commonly employed but often fall short in achieving optimal alignment and mechanical strength. Silk fibroin has emerged as a versatile material in tissue engineering, valued for its biocompatibility, mechanical robustness, and biodegradability. However, conventional electrospinning methods of SF result in randomly oriented fibers, limiting their efficacy. In this work, we developed a straightforward method to fabricate directional tissue scaffolds using silk fibroin. By integrating a magnetic field collecting device and incorporating Fe3O4 nanoparticles into the spinning solution, we successfully produced well-aligned silk nanofiber scaffolds. These aligned fibers not only improved scaffold orientation and mechanical properties but also exhibited magnetic responsiveness. The aligned SF scaffolds effectively guided the adhesion, proliferation, and differentiation of mesenchymal stem cells along the fiber direction. Cultured on these scaffolds, myoblast C2C12 cells demonstrated oriented growth, highlighting the potential of aligned SF fibers in advancing skeletal muscle engineering for biomedical applications.

An ultrastructure analysis of the developing human anterior cruciate ligament tibial enthesis.

This study aimed to investigate the ultrastructural anatomy of the developing ACL tibial enthesis. We hypothesized that enthesis architecture would progressively mature and remodel, eventually resembling that of the adult by the early postnatal stage. Five fresh-frozen human pediatric cadaveric knees aged 1-36 months underwent anatomical dissection to harvest the ACL insertion and underlying tibial chondroepiphysis. The samples were prepared for scanning electron microscopy (SEM) to examine the ultrastructural anatomy of the enthesis and underwent histological staining for circular polarized light (CPL) and light microscopy imaging. SEM analysis of the 1- and 8-month-old samples revealed a shallow interdigitation between the dense fibrous (ligamentous) tissue and unmineralized chondrogenic tissues, with a minimal transition zone. By 11-month, a more complex transition zone was present. By age 19- and 36-month-old, a progressively more complex and defined fibrocartilage zone was observed. CPL analysis revealed distinct collagen fiber continuity, alignment, and organization changes over time. By 19 and 36 months, the samples exhibited complex fiber arrangements and a progression toward uniform fiber orientation. Similarly, histological analysis demonstrated progressive remodeling of the enthesis with increasing age. Our results suggest that the ACL enthesis of the developing knee begins to mimic that of an adult as early as 19 months of age, as a more complex transition between ligamentous and chondro-epiphyseal tissue can be appreciated. We hypothesize that the observed changes are likely due to mechanical loading of the enthesis with the onset of weightbearing. Future investigations of ACL reconstruction and repair will benefit from improved understanding of the chondro-epiphyseal/ACL regions.

Tolerances of Alignment of Fibres to Photonic Integrated Circuits

Tolerances of Alignment of Fibres to Photonic Integrated Circuits

Paste extrusion‐based 3D printing of fiber‐reinforced ultra high‐temperature ceramics

AbstractUltra–high‐temperature ceramics (UHTCs) are valued for their extremely high melting temperatures and resistance to active oxidation. However, their low fracture strengths and the difficulties in shaping them into complex geometries hamper their widespread application. This study aims to fabricate zirconium diboride–silicon carbide (ZrB2‐SiC) composites reinforced with aligned SiC fibers by formulating suspensions containing a preceramic polymer, ZrB2, and SiC fibers. This study assessed the influence of fiber alignment on electrical and thermal conductivities, as well as on mechanical strength. The results revealed a significant enhancement in thermal conductivity, particularly when the fibers were aligned, effectively doubling it compared with the non‐aligned parts. Additionally, increasing the fiber content significantly improved the fracture strength, with composites containing 22.5 vol% fibers reaching fracture strengths over 57 MPa. However, the final values did not meet the theoretical expectations because the porosity in pyrolyzed parts exceeded 10%. Furthermore, the study demonstrated a 10‐fold increase in electrical conductivity with fiber alignment compared to that for non‐aligned composites. These results highlight the capability of paste extrusion‐based additive manufacturing in tailoring ultra–high‐temperature ceramic matrix composites (UHTCMCs) with aligned fibers, realizing their suitability for aerospace applications.

Electric Field-Induced Ordered-Structural Aerogels Enable Superinsulation and Multifunctionality.

1D flexible fibers assembled 3D porous networked ceramic fiber aerogels (CFAs) are developed to overcome the brittleness of traditional ceramic particle aerogels. However, existing CFAs with disordered and quasi-ordered structures fail to balance the relationship between flexibility, robustness, and thermal insulation. Creating novel architectural CFAs with an excellent combination of performances has proven extremely challenging. In this paper, a novel strategy is adopted to fabricate porous mullite fibrous aerogels (MFAs) with ordered structures by combining fiber sedimentation and electric field-induced fiber alignment techniques. For the first time, electric field-induced alignment of ceramic fibers is utilized to prepare bulk aerogels on a large scale. The resulting MFAs exhibit ultra-low high-temperature thermal conductivity of 0.0830 W m-1 K-1 at 1000°C, anisotropic mechanical and sound absorption performances, and multifunctionality in terms of the combination of thermal insulation, sound absorption, and hydrophobicity. The successful synthesis of such fascinating materials may provide new insights into the design and development of multifunctional CFAs for various applications.

Diseased Tendon Models Demonstrate Influence of Extracellular Matrix Alterations on Extracellular Vesicle Profile.

Tendons enable movement through their highly aligned extracellular matrix (ECM), predominantly composed of collagen I. Tendinopathies disrupt the structural integrity of tendons by causing fragmentation of collagen fibers, disorganization of fiber bundles, and an increase in glycosaminoglycans and microvasculature, thereby driving the apparent biomechanical and regenerative capacity in patients. Moreover, the complex cellular communication within the tendon microenvironment ultimately dictates the fate between healthy and diseased tendon, wherein extracellular vesicles (EVs) may facilitate the tendon's fate by transporting biomolecules within the tissue. In this study, we aimed to elucidate how the EV functionality is altered in the context of tendon microenvironments by using polycaprolactone (PCL) electrospun scaffolds mimicking healthy and pathological tendon matrices. Scaffolds were characterized for fiber alignment, mechanical properties, and cellular activity. EVs were isolated and analyzed for concentration, heterogeneity, and protein content. Our results show that our mimicked healthy tendon led to an increase in EV secretion and baseline metabolic activity over the mimicked diseased tendon, where reduced EV secretion and a significant increase in metabolic activity over 5 days were observed. These findings suggest that scaffold mechanics may influence EV functionality, offering insights into tendon homeostasis. Future research should further investigate how EV cargo affects the tendon's microenvironment.

A skin-inspired anisotropic multidimensional sensor based on low hysteresis organohydrogel with linear sensitivity and excellent robustness for directional perception

Human skin has complex sensors to perceive three-dimensional stimuli from the environment. Skin-inspired flexible sensors with multidimensional and directional perception are desirable for applications in intelligent robots and human–machine interaction. Herein, wearable multidimensional sensors have been fabricated by macroscopically assembling 3D-printed microstructured anisotropic organohydrogel sensory units through robust interfacial adhesion. The organohydrogel is crosslinked using microgels and starch microparticles through non-covalent interactions, and composited with short carbon fibers as conductive fillers. The physical network exhibits low hysteresis against 5000 cyclic loadings, which demonstrates excellent robustness in both mechanical properties and sensory performance. The organohydrogel precursor is printed into a cone-shaped sensor with a pressure sensitivity 50 times higher than that of its bulk counterpart. A sea cucumber epidermis-like microstructured sensor with abundant highly sensitive cone array is assembled with 3D-printed anisotropic gels with highly aligned carbon fibers inside, generating a multidimensional sensor capable of perceiving stimuli along X-, Y-, and Z-axis. The assembled sensor can directionally distinguish external forces and identify human motions. This study demonstrates a promising strategy to fabricate well-structured organohydrogel sensors for applications in electronic skin, biomimetic flexible electronics, and artificial intelligence.

Low magnetic field alignment of carbon fibers in a polymer matrix for high-performance thermal interface materials

Carbon-based materials like carbon nanotubes, graphene nanoplatelets, graphite, and carbon fibers (CF) are highly promising fillers for enhancing the thermal conductivity of thermal interface materials (TIMs) due to their high thermal conductivity and low thermal expansion. Aligning these fillers can further improve thermal conductivity, but current alignment methods using high magnetic fields are impractical for industrial use. In this study, we investigated the enhancement of the thermal conductivity of CF–polymer composites by aligning CF fillers with a low magnetic field. We observed up to 17 times enhancement of the thermal conductivity (from 3.1 to 52.8 W/mK) in a CF–graphene–polymer composite film by vertically aligning the CF fillers with a magnetic field of 0.75 T. The analysis of the structural properties of the films using X-ray diffraction and field-emission scanning electron microscopy imaging confirmed that the crystalline c-axis of the graphite plates in the CF was oriented perpendicular to the magnetic field direction. The large anisotropy in the diamagnetic susceptibility of the laminated graphene structure of the CF flakes is at the origin of the filler alignment. Furthermore, the thermal conductivity of the composites showed a strong correlation with the degree of filler alignment, which was dependent on the CF–graphene hybridization and the type of polymer matrix. This study provides a scalable and cost-effective method for enhancing the physical properties of carbon composites by controlling their microarchitecture using a low magnetic field.

Decentralized approach for incorporating waste wind turbine blades into 3D printing filaments using mechanical recycling

AbstractThe increasing awareness in environmental safety has led to rapid development in production of electricity using wind energy with wind turbines. The widespread deployment of wind turbines has outpaced the effective recycling of End‐of‐Life wind turbines. This study explores the potential of mechanically recycling decommissioned wind turbine blades (WTB) as reinforcement material in 3D printing processes. Utilizing mechanical grinding, materials were extracted from the waste blades and subsequently analyzed using Fourier transform infrared spectroscopy, Differential scanning calorimetry, and thermogravimetric analysis to determine optimal processing conditions. The reclaimed materials were then blended with recycled polypropylene through single‐screw extrusion to fabricate tensile test samples via Fused Deposition Modeling. The impact of print orientation on mechanical strength was examined at 0°, 45°, and 90° angles. Morphological analysis was conducted on the fractured specimens to assess the failure characteristics. The findings indicate that samples printed at a 90° orientation exhibited superior mechanical properties, suggesting a viable pathway for incorporating wind turbine waste into sustainable manufacturing cycles.Highlights A decentralized‐mechanical recycling technique to the waste WTB. The necessary material parameters for the operations employed in this study. Reinforced 3D printable filaments from waste WTB. Stronger reinforced filaments obtained from proper fiber alignment.

Full‐field effect of flow‐induced fiber orientation during compression molding of carbon fiber sheet molding compounds

AbstractAn image‐based fiber orientation analysis technique has been employed to study the effect of initial charge coverage and preferential fiber alignment on the flow‐induced fiber orientations in carbon fiber sheet molding compounds (SMCs). The initial charge coverage area exhibited minimal fiber reorientation while significant fiber alignment in the flow direction was observed in the regions of greatest flow. Novel subsurface analysis using the same full‐field orientation analysis technique also showed the presence of a skin‐core structure with greater flow‐induced fiber alignment at the mold surfaces, while the core retained more of the initial fiber orientation distribution. Edge effects were also revealed by this analysis at the mold walls. Tensile testing from two orthogonal directions showed that panels molded from lower charge coverage resulted in better mechanical performance and lower anisotropy. Moreover, by encouraging charge flow in the preform's preferential alignment direction, high tensile stiffness and strength in the preferred direction were achieved (56.7 GPa and 238.9 MPa, respectively) at 30% fiber volume fraction. This provides a practical demonstration of the value in controlling fiber orientation, with respect to charge positioning and mold flow, to maximize and tailor the composite performance of SMCs typically used for automotive applications.Highlights Low‐cost scanning technique is extended to assess internal fiber orientations Full‐field orientations are measured before and after molding Investigation of how charge size and shape can affect orientations Combining effects of flow and initial orientation to tailor SMC performance Circular statistics provides a thorough analysis of orientation distributions

Upcycling end-of-life carbon fiber in high-performance CFRP composites by the material extrusion additive manufacturing process

Each year, a significant amount of waste is produced from carbon fiber polymer composites at the end of its lifecycle due to extensive use across various applications. Utilizing regenerative carbon fiber as a feedstock material offers a promising and sustainable approach to additive manufacturing based on materials. This study proposes the additive manufacturing of recycled carbon fiber with a polyamide-12 polymer composite. Filaments of recycled carbon fiber-reinforced polyamide-12 (rCF-PA12) with different recycled carbon fiber contents (0%, 10%, and 15% by weight) in the polyamide-12 matrix are developed. These filaments are utilized for 3D printing of specimens by using various infill density parameters (80% and 100%) on a fused deposition modeling 3D printer. The study examined how the fiber content and infill densities influenced the flexural performance of the printed specimens. Notably, the part containing 15 wt% recycled carbon fiber (rCF) composites showed a significant improvement in flexural performance due to enhanced interface bonding and effective fiber alignment. The results indicated that reinforcing the printed part with 10% and 15 wt% recycled carbon fiber (rCF) improved the flexural properties by 49.86% and 91.75%, respectively, compared to the unreinforced printed part under the same infill density and printing parameters. The investigation demonstrates that the additive manufacturing-based technique presents a potential approach to use carbon fiber-reinforced polymers waste and manufacture high-performance engineering, economic, and environmentally friendly industrial applications with the complicated design using different polymer matrices.

Electrospun "Hard-Soft" Interpenetrating Nanofibrous Tissue Scaffolds Facilitating Enhanced Mechanical Strength and Cell Proliferation.

"Soft" hydrogel-based macroporous scaffolds have been widely used in tissue engineering and drug delivery applications due to their hydrated interfaces and macroporous structures, but have drawbacks related to their weak mechanics and often weak adhesion to cells. In contrast, "hard" poly(caprolactone) (PCL) electrospun fibrous networks have desirable mechanical strength and ductility but offer minimal interfacial hydration and thus limited capacity for cell proliferation. Herein, we demonstrate the fabrication of interpenetrating nanofibrous networks based on coelectrospun PCL and poly(oligoethylene glycol methacrylate) (POEGMA) nanofibers that exhibit the mechanical benefits of PCL but the interfacial hydration benefits of hydrogels. The electrospinning process results in partially aligned but interpenetrating fiber network with minimal internal phase separation, leading to anisotropic but strong mechanical properties even in the hydrated state; apparent ultimate tensile strengths of the swollen scaffolds ranged from 429 ± 39 kPa in the direction of fiber alignment (longitudinal) to 86 ± 25 kPa perpendicular to fiber alignment (cross-longitudinal), typical of PCL-based scaffolds and enabling efficient suture retention in different directions. However, contact angle measurements indicate hydrogel-like interfacial properties due to the presence of the interpenetrating POEGMA network. C2C12 myoblast proliferation in the PCL-POEGMA scaffolds was 50% higher than that observed on PCL-only scaffolds, a result attributed to the presence of the more hydrophilic POEGMA interpenetrating nanofiber network. Overall, this method is demonstrated to represent a facile single-step strategy to fabricate strong macroporous but still interfacially hydrophilic scaffolds for tissue engineering applications.

Modeling fiber alignment in 3D printed ultra-high-performance concrete based on stereology theory

This paper introduces a theoretical model for forecasting fiber orientation in 3D-printed ultra-high-performance concrete (3DP-UHPC). Initially, the dynamic evolution process of fiber alignment in 3DP-UHPC was characterized using X-ray computed tomography (X-CT) and image analysis. The results indicated that fiber alignment during extrusion process was primarily constrained by the rigid boundary of nozzle. Leveraging stereology theory, the regularity of fiber alignment affected by boundary effects was elucidated. Following layer deposition, the flattening effect resulting from the nozzle's extrusion force and gravity of upper layers influenced fiber alignment along printing direction. To quantify this impact, a flattening correction coefficient was introduced to modify fiber orientation coefficient in an ideal state. Finally, considering the overlapping effect of boundary and flattening on fiber orientation in 3DP-UHPC, a theoretical model was developed to predict fiber orientation. The model demonstrated robust adaptability, providing valuable insights into the design of 3DP-UHPC with improved fiber reinforcement efficiency.

Geometric characteristics of stromal collagen fibres in breast cancer using differential interference contrast microscopy.

Breast cancer (BC) is characterised by a high level of heterogeneity, which is influenced by the interaction of neoplastic cells with the tumour microenvironment. The diagnostic and prognostic role of the tumour stroma in BC remains to be defined. Differential interference contrast (DIC) microscopy is a label-free imaging technique well suited to visualise weak optical phase objects such as cells and tissue. This study aims to compare stromal collagen fibre characteristics between in situ and invasive breast tumours using DIC microscopy and investigate the prognostic value of collagen parameters in BC. A tissue microarray was generated from 200 cases, comprising ductal carcinoma in situ (DCIS; n=100) and invasive tumours (n=100) with an extra 50 (25 invasive BC and 25 DCIS) cases for validation was utilised. Two sections per case were used: one stained with haematoxylin and eosin (H&E) stain for histological review and one unstained for examination using DIC microscopy. Collagen fibre parameters including orientation angle, fibre alignment, fibre density, fibre width, fibre length and fibre straightness were measured. Collagen fibre density was higher in the stroma of invasive BC (161.68±11.2fibre/µm2) compared to DCIS (p<0.0001). The collagen fibres were thinner (13.78±1.08µm), straighter (0.96±0.006, on a scale of 0-1), more disorganised (95.07°±11.39°) and less aligned (0.20±0.09, on a 0-1 scale) in the invasive BC compared to DCIS (all p<0.0001). A model considering these features was developed that could distinguish between DCIS and invasive tumours with 94% accuracy. There were strong correlations between fibre characteristics and clinicopathological parameters in both groups. A statistically significant association between fibre characteristics and patients' outcomes (breast cancer specific survival, and recurrence free survival) was observed in the invasive group but not in DCIS. Although invasive BC and DCIS were both associated with stromal reaction, the structural features of collagen fibres were significantly different in the two disease stages. Analysis of the stroma fibre characteristics in the preoperative core biopsy specimen may help to differentiate pure DCIS from those associated with invasion.

Bioengineering Strategy to Promote CNS Nerve Growth and Regeneration via Chronic Glutamate Signaling

Being part of the mature mammalian central nervous system, impairments of the retina and optic nerves caused by trauma or diseases often cannot be restored. Progressive degeneration of retinal ganglion cells (RGCs) in glaucoma and other optic neuropathies gradually leads to permanent vision loss, which currently has no cure. The purpose of this study is to develop a biocompatible scaffold to support RGC survival and guide axon growth, facilitating optic nerve repair and regeneration. We here report that electrical stimulation (ES) significantly promoted neurite outgrowth and elongation from primary RGCs, mediated through glutamate receptor signaling. To mimic prolonged glutamate stimulation and facilitate sustained nerve growth, we fabricated biocompatible poly-γ-benzyl-L-glutamate (PBG) scaffolds for controlled glutamate release. These PBG scaffolds supported RGC survival and robust long-distance nerve growth in both retinal explants and isolated RGC cultures. In contrast, control polycaprolactone (PCL) scaffolds with similar physical structures showed little benefits on RGC survival or nerve growth. Moreover, PBG scaffolds promoted the differentiation and neurite outgrowth from embryonic stem cell-derived RGC progenitors. The aligned PBG scaffold drove directed nerve elongation along the fiber alignment. Transplantation of PBG-coated biocompatible conduits induced robust optic nerve regeneration in adult mice following nerve transection. Together, the findings present the exciting possibility of driving optic nerve regeneration and RGC progenitor cell differentiation by imitating ES or glutamate signaling. PBG presents a permissive biomaterial in supporting robust and directed axon growth with promising clinical applications in the future. Statement of SignificanceWe here reported compelling findings that demonstrate the potent regenerative effects of a bioengineered scaffold incorporating poly-γ-benzyl-L-glutamate (PBG) on the optic nerve. Retinal ganglion cell (RGC) axons, which form the optic nerve, are incapable of regenerating in adulthood, posing a significant hurdle in restoring vision for patients with optic nerve diseases or injuries. Built upon the finding that electrical stimulation promotes RGC axonal growth through glutamate signaling, we developed PBG scaffolds to provide sustained glutamate stimulation and showed their exceptional effects on driving directed axonal elongation in cultured RGCs and neural progenitors, as well as supporting robust optic nerve regeneration after transection in vivo. The findings hold great promise for reversing vision loss in patients with optic nerve conditions.

Fiber Alignment's Effect on the Properties of Hybrid Glass/Flax Fiber‐Reinforced Epoxy Composite Laminates

ABSTRACTIn this study, glass fiber and flax fiber reinforced with epoxy and ZnO nanofiller were used to create composites utilizing the hand layup method. The purpose of this study is to develop a novel hybrid polymer‐matrix composite that can be employed in various application areas such as aerospace, sports, medical equipment, railways, etc. The fabricated composite was made with epoxy as a matrix material reinforced with nano‐ZnO, glass fiber, and flax fiber. Six fiber layers with varying fiber orientations were inserted into the matrix in a specific stacking order. The results show the maximum tensile, flexural, impact, and ILSS as the values of 264.74 MPa, 492.12 MPa, 595.72 J/m, and 50.05, respectively. Along with the mechanical properties, Physical characterization such as density, void content, thickness swelling, moisture content, and water absorption tests were conducted. FE‐SEM test was conducted to check the uniformity of nanoparticles in the matrix material and the breakdown of fibers.

Harnessing interpretable and ensemble machine learning techniques for precision fabrication of aligned micro-fibers

Electrospinning is a robust technique for producing micro/nano-scale fibrous structures, influenced by intricate interplays of fluid dynamics, aerodynamics, and electromagnetic forces. Depending on the desired outcome, these fibers can adopt various morphologies, including solid, tubular, concentric, and gradient. Such morphologies are modulated by parameters such as collector configuration, flow rate, voltage, solution properties, and nozzle dimensions. However, the task of modeling and predicting these multifaceted morphologies remains complex. Aligned microfibers with 3D orientation hold promise in tissue engineering, regenerative medicine, and drug delivery, necessitating meticulous control over the fabrication parameters. In our research, we tapped into machine learning (ML) to address these challenges. Classification ML models were designed to predict fibrous patterns—aligned, random, or jet branching—based on determinants like voltage, flow rate, and collector configurations. Notably, the Random Forest (RF) and Support Vector Machine (SVM) models, especially with radial kernel-trick, displayed outstanding predictive capabilities on the test data. Furthermore, regression-based ML was harnessed to discern fiber alignment coherency and inter-fiber distances. Models such as Lasso and Ridge regression elucidated predictive coefficients for these characteristics, while ensemble models, like gradient-boosting (GB) decision trees (DT), showcased prowess in regression scenarios. Key findings spotlighted the significance of parameters like plate gap for alignment coherency and needle-to-collector distance for inter-fiber spacing. As we strive to gain granular control over micro/nano feature morphology in electrospinning, understanding predictor-response dynamics is imperative. Our investigation underscores the essential role of ML in enhancing both qualitative and quantitative precision in fabricating advanced fibrous structures. Moreover, fusing ML with real-time process monitoring offers groundbreaking potential, particularly in Bio-Fabrication, regenerative medicine, and tissue engineering, where high-precision manufacturing remains a top priority.

3D melt blowing of Elastollan thermoplastic polyurethane for tissue engineering applications: A pilot study

Scaffolds, in addition to being biocompatible, should possess structural and mechanical properties similar to the natural tissues they intend to replace. Many tissue engineering applications require porous 3D scaffolds characterized by unique microfibrous organization and mechanical anisotropy. Manufacturing process principles and process parameter-biomaterial interactions ultimately govern the properties that can be achieved in the scaffold. In this study, we investigate a recently developed nonwoven scaffold fabrication process, 3D melt blowing (3DMB), for processing Elastollan®, a thermoplastic polyurethane with basic mechanical properties suitable for musculoskeletal tissue engineering. The range of feasible processing parameters was screened and the effects of two sets of critical process parameters (fiber deposition offset and surface velocity of the collector) that produced contrasting scaffold morphologies were assessed. Results showed that scaffolds of Group B that were fabricated at the higher fiber deposition offset (90 %) and higher surface velocity of the collector (6 × 105 mm/min) possessed significantly smaller fiber diameter and higher porosity and degree of fiber alignment along the principal direction of collector rotation during 3DMB (all p < 0.05) compared to Group A scaffolds (fabricated at 50 % offset and 1 × 105 mm/min surface velocity). Although both groups possessed similar tensile stiffness, the elongation at failure was significantly different (p < 0.0001). The higher elongation at failure of Group B correlated with the higher degree of fiber alignment in these scaffolds. In contrast, the more isotropic fibrous organization of Group A contributed to their higher compressive stiffness (p = 0.004). The introduction of NaOH treatment to improve hydrophilicity of the scaffolds resulted in a significant reduction of tensile stiffness of Group A (p < 0.05) but not Group B. This treatment did not significantly affect the elongation at failure or compressive stiffness of both groups. With NaOH-treatment, both groups demonstrated good biocompatibility when seeded with fibroblast cells over 14 days. This study confirms the ability to fabricate via 3DMB, biocompatible, micro-fibrous, Elastollan scaffolds relevant for musculoskeletal tissue engineering.