Melt Electrospinning Writing of Highly Ordered Large Volume Scaffold Architectures

3D printed dual macro-, microscale porous network as a tissue engineering scaffold with drug delivering function

Tissue engineering macroporous scaffolds are important for regeneration of large volume defects resulting from diseases such as breast or bone cancers. Another important part of the treatment of these conditions is adjuvant drug therapy to prevent disease recurrence or surgical site infection. In this study, we developed a new type of macroporous scaffolds that have drug loading and release functionality to use in these scenarios. 3D printing allows for building macroporous scaffolds with deterministically designed complex architectures for tissue engineering yet they often have low surface areas thus limiting their drug loading capability. In this proof-of-concept study, we aimed to introduce microscale porosity into macroporous scaffolds to allow for efficient yet simple soak-loading of various clinical drugs and control their release. Manufacturing of scaffolds having both macroporosity and microscale porosity remains a difficult task. Here, we combined porogen leaching and 3D printing to achieve this goal. Porogen microparticles were mixed with medical grade polycaprolactone and extruded into scaffolds having macropores of 0.7 mm in size. After leaching, intra-strut microscale pores were realized with pore size of 20-70 μm and a total microscale porosity of nearly 40%. Doxorubicin (DOX), paclitaxel (PTX) and cefazolin (CEF) were chosen as model drugs of different charges and solubilities to soak-load the scaffolds and achieved loading efficiency of over 80%. The microscale porosity was found to significantly reduce the burst release allowing the microporous scaffolds to release drugs up to 200, 500 and 150 h for DOX, PTX and CEF, respectively. Finally, cell assays were used and confirmed the bioactivities and dose response of the drug-loaded scaffolds. Together, the findings from this proof-of-concept study demonstrate a new type of scaffolds with dual micro-, macro-porosity for tissue engineering applications with intrinsic capability for efficient loading and sustained release of drugs to prevent post-surgery complications.

Tailored Melt Electrowritten Scaffolds for the Generation of Sheet-Like Tissue Constructs from Multicellular Spheroids

Melt electrowriting (MEW) is an additive manufacturing technology that is recently used to fabricate voluminous scaffolds for biomedical applications. In this study, MEW is adapted for the seeding of multicellular spheroids, which permits the easy handling as a single sheet-like tissue-scaffold construct. Spheroids are made from adipose-derived stromal cells (ASCs). Poly(ε-caprolactone) is processed via MEW into scaffolds with box-structured pores, readily tailorable to spheroid size, using 13-15 µm diameter fibers. Two 7-8 µm diameter "catching fibers" near the bottom of the scaffold are threaded through each pore (360 and 380 µm) to prevent loss of spheroids during seeding. Cell viability remains high during the two week culture period, while the differentiation of ASCs into the adipogenic lineage is induced. Subsequent sectioning and staining of the spheroid-scaffold construct can be readily performed and accumulated lipid droplets are observed, while upregulation of molecular markers associated with successful differentiation is demonstrated. Tailoring MEW scaffolds with pores allows the simultaneous seeding of high numbers of spheroids at a time into a construct that can be handled in culture and may be readily transferred to other sites for use as implants or tissue models.

A new prototype melt-electrospinning device for the production of biobased thermoplastic sub-microfibers and nanofibers

Sub-microfibers and nanofibers have a high surface-to-volume ratio, which makes them suitable for diverse applications including environmental remediation and filtration, energy production and storage, electronic and optical sensors, tissue engineering, and drug delivery. However, the use of such materials is limited by the low throughput of established manufacturing technologies. This short report provides an overview of current production methods for sub-microfibers and nanofibers and then introduces a new melt-electrospinning prototype based on a spinneret with 600 nozzles, thereby providing an important step towards larger-scale production. The prototype features an innovative collector that achieves the optimal spreading of the fiber due to its uneven surface, as well as a polymer inlet that ensures even polymer distribution to all nozzles. We prepared a first generation of biobased fibers with diameters ranging from 1.000 to 7.000 μm using polylactic acid and 6% (w/w) sodium stearate, but finer fibers could be produced in the future by optimizing the prototype and the composition of the raw materials. Melt electrospinning using the new prototype is a promising method for the production of high-quality sub-microfibers and nanofibers.

Spinning and Applications of Bioinspired Fiber Systems

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

Fabrication of Ultrafine PPS Fibers with High Strength and Tenacity via Melt Electrospinning

Electrospinning (e-spinning) is an emerging technique to prepare ultrafine fibers. Polyphenylene sulfide (PPS) is a high-performance resin which does not dissolve in any solvent at room temperature. Commercial PPS fibers are produced mainly by meltblown or spunbonded process to give fibers ~20 μm in diameter. In this research, an in-house designed melt electrospinning device was used to fabricate ultrafine PPS fibers, and the e-spinning operation conducted under inert gas to keep PPS fibers from oxidizing. Under the optimum e-spinning conditions (3 mm of nozzle diameter, 30 kV of electrostatic voltage, and 9.5 cm of tip-to-collector distance), the as-spun fibers were less than 8.0 μm in diameter. After characterization, the resultant PPS fibers showed uniform diameter and structural stability. Compared with commercial PPS staple fibers, the obtained fibers had a cold crystallization peak and 10 times higher storage modulus, thereby offering better tensile tenacity and more than 400% elongation at break.

Mediating human stem cell behaviour via defined fibrous architectures by melt electrospinning writing

The architecture within which cells reside is key to mediating their specific functions within the body. In this study, we use melt electrospinning writing (MEW) to fabricate cell micro-environments with various fibrous architectures to study their effect on human stem cell behaviour. We designed, built and optimised a MEW apparatus and used it to fabricate four different platform designs of 10.4 ± 2 μm fibre diameter, with angles between fibres on adjacent layers of 90°, 45°, 10° and R (random). Mechanical characterisation was conducted via tensile testing, and human skeletal stem cells (hSSCs) were seeded to scaffolds to study the effect of architecture on cell morphology and mechanosensing (nuclear YAP). Cell morphology was significantly altered between groups, with cells on 90° scaffolds having a lower aspect ratio, greater spreading, greater cytoskeletal tension and nuclear YAP expression. Long term cell culture studies were then conducted to determine the differentiation potential of scaffolds in terms of alkaline phosphatase activity, collagen and mineral production. Across these studies, an increased cell spreading in 3-dimensions is seen with decreasing alignment of architecture correlated with enhanced osteogenesis. This study therefore highlights the critical role of fibrous architecture in regulating stem cell behaviour with implications for tissue engineering and disease progression.

STATEMENT OF SIGNIFICANCE

This is the first study which has investigated the effect of controlled fibrous architectures fabricated via melt electrospinning writing on stem cell behaviour and differentiation. After optimising the fabrication process and characterising scaffolds via SEM and mechanical testing, skeletal stem cells were seeded onto fibrous scaffolds with various micro-architectures. These architectures drove cell shape changes resulting in architecture dependent nuclear YAP localisation, suggesting altered mechanosensing at early time points. In agreement with these early markers, long term cell culture studies revealed for the first time that a 90° fibrous architecture is optimal for the osteogenic differentiation of skeletal stem cells.