Electrospun Filaments Research Articles

A Hybrid Electrospun-Extruded Polydioxanone Suture for Tendon Tissue Regeneration.

Many surgical tendon repairs fail despite advances in surgical materials and techniques. Tendon repair failure can be partially attributed to the tendon's poor intrinsic healing capacity and the repurposing of sutures from other clinical applications. Electrospun materials show promise as a biological scaffold to support endogenous tendon repair, but their relatively low tensile strength has limited their clinical translation. It is hypothesized that combining electrospun fibers with a material with increased tensile strength may improve the suture's mechanical properties while retaining biophysical cues necessary to encourage cell-mediated repair. This article describes the production of a hybrid electrospun-extruded suture with a sheath of submicron electrospun fibers and a core of melt-extruded fibers. The porosity and tensile strength of this hybrid suture is compared with an electrospun-only braided suture and clinically used sutures Vicryl and polydioxanone (PDS). Bioactivity is assessed by measuring the adsorbed serum proteins on electrospun and melt-extruded filaments using mass spectrometry. Human hamstring tendon fibroblast attachment and proliferation were quantified and compared between the hybrid and control sutures. Combining an electrospun sheath with melt-extruded cores created a hybrid braid with increased tensile strength (70.1 ± 0.3N) compared with an electrospun only suture (12.9 ± 1 N, p < 0.0001). The hybrid suture had a similar force at break to clinical sutures, but lower stiffness and stress. The Young's modulus was 772.6 ± 32 MPa for the hybrid suture, 1693.0 ± 69 MPa for PDS, and 3838.0 ± 132 MPa for Vicryl, p < 0.0001. Hybrid sutures had lower overall porosity than electrospun-only sutures (40 ± 4% and 60 ± 7%, respectively, p = 0.0018) but had a significantly larger overall porosity and average pore diameter compared with surgical sutures. There were similar clusters of adsorbed proteins on electrospun and melt-extruded filaments, which were distinct from PDS. Tendon fibroblast attachment and cell proliferation on hybrid and electrospun sutures were significantly higher than on clinical sutures. This study demonstrated that a bioactive suture with increased tensile strength and lower stiffness could be produced by adding a core of 10 μm melt-extruded fibers to a sheath of electrospun fibers. In contrast to currently used sutures, the hybrid sutures promoted a bioactive response: serum proteins adsorbed, and fibroblasts attached, survived, grew along the sutures, and adopted appropriate morphologies.

Manufacture of Soft‐Hard Implants from Electrospun Filaments Embedded in 3D Printed Structures

Manufacture of Soft‐Hard Implants from Electrospun Filaments Embedded in 3D Printed Structures

Manufacture of Soft-Hard Implants from Electrospun Filaments Embedded in 3D Printed Structures.

Rotator cuff tendon tears are common injuries of the musculoskeletal system that often require surgical repair. However, re-tearing following repair is a significant clinical problem, with a failure rate of up to 40%, notably at the transition from bone to tendon. The development of biphasic materials consisting of soft and hard components, which can mimic this interface, is therefore promising. Here, a simple manufacturing approach is proposed that combines electrospun filaments and 3D printing to achieve scaffolds made of a soft polydioxanone cuff embedded in a porous polycaprolactone block. The insertion area of the cuff is based on the supraspinatus tendon footprint and the size of the cuff is scaled up from 9 to 270 electrospun filaments to reach a clinically relevant strength of 227N on average. The biological evaluation shows that the biphasic scaffold components are noncytotoxic, and that tendon and bone cells can be grown on the cuff and block, respectively. Overall, these results indicate that combining electrospinning and 3D printing is a feasible and promising approach to create soft-to-hard biphasic scaffolds that can improve the outcomes of rotator cuff repair.

Early development of a polycaprolactone electrospun augment for anterior cruciate ligament reconstruction

Despite the clinical success of Anterior Cruciate Ligament reconstruction (ACLR) in some patients, unsatisfactory clinical outcomes secondary to graft failure are seen, indicating the need to develop new regeneration strategies. The use of degradable and bioactive textiles has the potential to improve the biological repair of soft tissue. Electrospun (ES) filaments are particularly promising as they have the ability to mimic the structure of natural tissues and influence endogenous cell behaviour. In this study, we produced continuous polycaprolactone (PCL) ES filaments using a previously described electrospinning collection method. These filaments were stretched, twisted, and assembled into woven structures. The morphological, tensile, and biological properties of the woven fabric were then assessed. Scanning electron microscopy (SEM) images highlighted the aligned and ACL-like microfibre structure found in the stretched filaments. The tensile properties indicated that the ES fabric reached suitable strengths for a use as an ACLR augmentation device. Human ACL-derived cell cultured on the fabric showed approximately a 3-fold increase in cell number over 2 weeks and this was equivalent to a collagen coated synthetic suture commonly used in ACLR. Cells generally adopted a more elongated cell morphology on the ES fabric compared to the control suture, aligning themselves in the direction of the microfibres. A NRU assay confirmed that the ES fabric was non-cytotoxic according to regulatory standards. Overall, this study supports the development of ES textiles as augmentation devices for ACLR.

Pyridine as an additive to improve the deposition of continuous electrospun filaments.

Electrospun filaments are leading to a new generation of medical yarns that have the ability to enhance tissue healing through their biophysical cues. We have recently developed a technology to fabricate continuous electrospun filaments by depositing the submicron fibres onto a thin wire. Here we investigate the influence of pyridine on the fibre deposition. We have added pyridine to polydioxanone solutions at concentrations ranging from 0 to 100 ppm, increasing the conductivity of the solutions almost linearly from 0.04 uS/cm to 7 uS/cm. Following electrospinning, this led to deposition length increasing from 1 cm to 14 cm. The samples containing pyridine easily underwent cold drawing. The strength of drawn filaments increased from 0.8 N to 1.5 N and this corresponded to a decrease in fibre diameter, with values dropping from 2.7 μm to 1 μm. Overall, these findings are useful to increase the reliability of the manufacturing process of continuous electrospun filaments and to vary their biophysical properties required for their application as medical yarns such as surgical sutures.

Electrospun Filaments Embedding Bioactive Glass Particles with Ion Release and Enhanced Mineralization.

Efforts in tissue engineering aim at creating scaffolds that mimic the physiological environment with its structural, topographical and mechanical properties for restoring the function of damaged tissue. In this study we introduce composite fibres made by a biodegradable poly(lactic acid) (PLLA) matrix embedding bioactive silica-based glass particles (SBA2). Electrospinning is performed to achieve porous PLLA filaments with uniform dispersion of bioactive glass powder. The obtained composite fibres show in aligned arrays significantly increased elastic modulus compared with that of neat polymer fibres during uniaxial tensile stress. Additionally, the SBA2 bioactivity is preserved upon encapsulation as highlighted by the promoted deposition of hydroxycarbonate apatite (HCA) upon immersion in simulated body fluid solutions. HCA formation is sequential to earlier processes of polymer erosion and ion release leading to acidification of the surrounding solution environment. These findings suggest PLLA-SBA2 fibres as a composite, multifunctional system which might be appealing for both bone and soft tissue engineering applications.

Electro-spun PLA-PEG-yarns for tissue engineering applications

Electro-spinning is widely used in tissue-engineered applications mostly in form of non-woven structures. The development of e-spun yarn opens the door for textile fabrics which combine the micro to nanoscale dimension of electro-spun filaments with three-dimensional (3D) drapable textile fabrics. Therefore, the aim of the study was the implementation of a process for electro-spun yarns. Polylactic acid (PLA) and polyethylene glycol (PEG) were spun from chloroform solutions with varying PLA/PEG ratios (100:0, 90:10, 75:25 and 50:50). The yarn samples produced were analyzed regarding their morphology, tensile strength, water uptake and cytocompatibility. It was found that the yarn diameter decreased when the funnel collector rotation was increasd, however, the fiber diameter was not influenced. The tensile strength was also found to be dependent on the PEG content. While samples composed of 100% PLA showed a tensile strength of 2.5±0.7 cN/tex, the tensile strength increased with a decreasing PLA content (PLA 75%/PEG 25%) to 6.2±0.5 cN/tex. The variation of the PEG content also influenced the viscosity of the spinning solutions. The investigation of the cytocompatibility with endothelial cells was conducted for PLA/PEG 90:10 and 75:25 and indicated that the samples are cytocompatible.

Investigating the use of curcumin-loaded electrospun filaments for soft tissue repair applications.

Electrospun filaments represent a new generation of medical textiles with promising applications in soft tissue repair. A potential strategy to improve their design is to combine them with bioactive molecules. Curcumin, a natural compound found in turmeric, is particularly attractive for its antioxidant, anti-inflammatory, and antimicrobial properties. However, investigating the range of relevant doses of curcumin in materials designed for tissue regeneration has remained limited. In this paper, a wide range of curcumin concentrations was explored and the potential of the resulting materials for soft tissue repair applications was assessed. Polydioxanone (PDO) filaments were prepared with various amounts of curcumin: 0%, 0.001%, 0.01%, 0.1%, 1%, and 10% (weight to weight ratio). The results from the present study showed that, at low doses (≤0.1%), the addition of curcumin has no influence on the spinning process or on the physicochemical properties of the filaments, whereas higher doses lead to smaller fiber diameters and improved mechanical properties. Moreover, filaments with 0.001% and 0.01% curcumin stimulate the metabolic activity and proliferation of normal human dermal fibroblasts (NHDFs) compared with the no-filament control. However, this stimulation is not significant when compared to the control filaments (0%). Highly dosed filaments induce either the inhibition of proliferation (with 1%) or cell apoptosis (with 10%) as a result of the concentrations of curcumin found in the medium (9 and 32 μM, respectively), which are near or above the known toxicity threshold of curcumin (~10 μM). Moreover, filaments with 10% curcumin increase the catalase activity and glutathione content in NHDFs, indicating an increased production of reactive oxygen species resulting from the large concentration of curcumin. Overall, this study suggested that PDO electrospun filaments loaded with low amounts of curcumin are more promising compared with higher concentrations for stimulating tissue repair. This study also highlighted the need to explore lower concentrations when using polymers as PDO, such as those with polycaprolactone and other degradable polyesters.

Polystyrene comb architectures as model systems for the optimized solution electrospinning of branched polymers

The bead to bead-free fibers transition for electrospun filaments was investigated for well-defined linear and comb homopolymers. A series of monodisperse model comb structures with well-defined backbone and side chains was synthesized using anionic polymerization of polystyrene (PS). All model combs had the same backbone and a similar total molecular weight. The length and number of branches was varied, but the total number of monomers in the side chains was nearly constant. Solutions of these polystyrenes in N,N-dimethylformamide (DMF) were electrospun under identical conditions to determine the effect of molecular topology on the morphology of the fibers. The morphology and fiber diameter for all PS model polymers depended on the zero shear viscosity, η0. The comb solutions generally formed fibers at lower η0 and the fibers had larger diameters compared with linear polystyrene. The bead to fiber transition occurred at substantially lower polymer concentrations for combs with fewer, but longer branches.

Fabrication of continuous electrospun filaments with potential for use as medical fibres

Soft tissue injuries represent a substantial and growing social and economic burden. Medical fibres are commonly used to repair these injuries during surgery. Patient’s outcomes are, however, not promising with around 40% of surgical repairs failing within the first few months after surgery due to poor tissue regeneration. The application of nanofibrous filaments and yarns as medical fibres and scaffolds has been suggested to improve soft tissue regeneration and enhance the quality of the repair. However, due to a lack of robustness and reliability of the current fabrication methods, continuous nanofibrous filaments cannot be manufactured and scaled up in industrial settings and are not currently available for clinical use. We have developed a robust and automated method that enables the manufacture of continuous electrospun filaments and which has the potential to be integrated into existing textile production lines. The technology uses a wire guide to form submicrofibres in a dense, narrow mesh which can be detached as a long and continuous thread. The thread can then be stretched and used to create multifilament yarns which can imitate the hierarchical architecture of tissues such as tendons and ligaments. Electrospun polydioxanone yarns produced by this method showed improved cellular proliferation and adhesion when compared to medical monofilament fibres in current clinical use. In vivo, the electrospun yarns showed a good safety profile with mild foreign body reaction and complete degradation within 5 months after implantation. These results suggest that this filament collection method has the potential to become a useful platform for the fabrication of future medical textiles.

Evolution of fiber morphology during electrospinning

AbstractIn this study, the morphological evolution of poly(acrylonitrile) (PAN) nanofibers during electrospinning was examined via immersion precipitation of newly electrospun filaments in ethanol, and subsequently associating the fiber morphologies with the electrospinning distances (2 to 10 cm). We have observed that an uneven fiber stretching happened throughout the electrospinning process. A massive filament‐thinning took place at the initial stage of whipping instability, and fiber stretching at the later whipping stage was mainly concentrated on the bead sections, leading to improved uniformity of the resultant fibers. This work has provided a new insight into the fiber formation mechanism in the electrospinning process. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010

Fabrication of Aligned Poly(L‐lactide) Fibers by Electrospinning and Drawing

AbstractA new target collector was designed for taking up aligned nanofibers by electrospinning. The collector consists of a rotor around which several fins were attached for winding electrospun filaments continuously in large amounts. The alignment of the nanofibers wound on the collector was affected by the electrospinning conditions, such as the needle‐to‐collector distance and the applied voltage, but not by the rotation speed of the collector. At a voltage of 0.5 kV · cm−1, about 60% of the fibers were found to be aligned within an angle of ± 5° relative to the rotational direction of the collector. The fiber alignment was improved to 90% by drawing the fiber bundle 2–3 times at 110 °C. The drawing was also effective for crystal orientation of the fibers as revealed by WAXD. The drawn fibers show improved mechanical properties.magnified image

Continuous Concentric Lamellar Block Copolymer Nanofibers with Long Range Order

Fibers with long-range ordered internal structures have applications in various areas such as photonic band gap fibers, optical waveguides, wearable power, sensors, and sustained drug release. Up to now, such fibers have been formed by melt extrusion or drawing from a macroscopic preformed rod and were typically limited to diameters >10 microm with internal features >1 microm (Abouraddy, A. F.; et al. Nat. Mater. 2007, 6, 336). We describe a new class of continuous fibers and fibrous membranes with long-range ordered concentric lamellar structure that have fiber diameters and feature sizes 2-3 orders of magnitude smaller than those made by conventional methods. These fibers are created through confined self-assembly of block copolymers within core-shell electrospun filaments. In contrast to the copolymer in bulk or thin films, the domains of the concentric lamellar structure are shown here to vary quantitatively with (radial) position and to exhibit a novel dislocation that accommodates variations in fiber diameter robustly, permitting for the first time the realization of long-range order in technologically meaningful, continuous fibers with approximately 300 nm diameter and 50 nm radial period.

Electrospun Porous Mats for High Efficiency Filtration

Submicron size fibers (so-called nanofibers) are easily produced with an electrospinning apparatus from polymer solutions of poly(ethylene oxide), poly(vinyl alcohol), and polyamide-6. Electrospinning seems the most powerful tool for fabricating polymer nanofibers. Fibers were directly deposited in the form of random fiber webs with high area-to-volume ratio and small porous size on ordinary nonwoven filters of PET microfibers. Morphology and diameter distribution of the electrospun filaments were characterized by SEM investigations. The flow resistance of the produced composite filters are evaluated by means of air permeability measurements. The electrospun fibers have diameters ranging from about 70—500 nm and are interconnected each other to form thin webs that have very small pore size. After the electrospinning treatment, the air permeability of the filter media decreases 6—17 times showing a significant change of flow resistance that can be controlled by the thickness of nanofibers layer and the pore size. High efficiency nano-microfibers composite filters could be used in a wide range of applications, ranging from air cleaning for automotive to environment conditioning or liquid filtration.

How is it possible to produce highly oriented yarns of electrospun fibers?

AbstractElectrospinning of polymeric nanofibers onto a stationary grounded target produces a nonwoven mat‐like material. Using a rapidly rotating grounded target in the form of a wheel or belt, it is possible to produce significant lengths of highly oriented yarns of electrospun filaments. This observation is difficult to explain when one compares the calculated velocity of an electrospun monofilament with the surface velocity of the grounded target. This study was undertaken to attempt to answer this question. Are the calculated fiber velocities correct? Is the collected electrospun filament really a monofilament? Does the electrospun filament split into multiple filaments or do fibers loop in an oriented manner on the collection wheel? POLYM. ENG. SCI., 47:1530–1535, 2007. © 2007 Society of Plastics Engineers

Processing and microstructural characterization of porous biocompatible protein polymer thin films

The process of electrostatic fiber formation, or electrospinning, was used to create biocompatible thin films for use in implantable devices. The morphology of the thin films was found to depend on process parameters including solution concentration, applied electric field strength, deposition distance, and deposition time. The microstructure of the coatings was examined by Transmission Electron Microscopy (TEM) and Wide-Angle X-ray Scattering (WAXS), with electrospun filaments being weakly oriented along the fiber axis. A shish kebab model for the filament morphology was proposed. The electrospinning process was shown to be a means of creating porous thin films with structural gradients and controlled morphology that could enhance biocompatibility.