Effect of process parameters on properties of wet-spun poly(L,D-lactide) copolymer multifilament fibers

Improved Thermal Processing of Polylactic Acid/Oxidized Starch Composites and Flame-Retardant Behavior of Intumescent Non-Wovens

Thermoplastic processing and spinning of native starch is very challenging due to (a) the linear and branched polymers (amylose and amylopectin) present in its structure and (b) the presence of inter-and-intramolecular hydrogen bond linkages in its macromolecules that restrict the molecular chain mobility. Therefore, in this study, oxidized starch (OS) (obtained after oxidation of native starch with sodium perborate) was melt-blended with polylactic acid (PLA) polymer to prepare PLA/OS blends that were then mixed together with ammonium polyphosphate (APP), a halogen-free flame retardant (FR) used as acid donor in intumescent formulations on twin-screw extruder to prepare PLA/OS/APP composites. OS with different concentrations also served as bio-based carbonic source in intumescent formulations. PLA/OS/APP composites were melt spun to multifilament fibers on pilot scale melt-spinning machine and their crystallinity and mechanical properties were optimized by varying spinning parameters. The crystallinity of the fibers was studied by differential scanning calorimetry and thermal stabilities were analyzed by thermogravimetric analysis. Scanning electron microscopy was used to investigate the surface morphology and dispersion of the additives in the fibers. Needle-punched non-woven fabrics from as prepared melt-spun PLA/OS/APP fibers were developed and their fire properties such as heat release rate, total heat release, time to ignition, residual mass % etc. by cone calorimetry test were measured. It was found that PLA/OS/APP composites can be melt spun to multifilament fibers and non-woven flame-retardant fabrics produced thereof can be used in industrial FR applications.

Additive manufacturing of star poly(ε-caprolactone) wet-spun scaffolds for bone tissue engineering applications

Three-dimensional fibrous scaffolds made of a three-arm star poly(ε-caprolactone) were developed by employing a novel computer-aided wet-spinning apparatus to precisely control the deposition pattern of an extruded polymeric solution as a filament into a coagulation bath. Star poly(ε-caprolactone)/hydroxyapatite composite scaffolds composed of fibres with a porous morphology both in the outer surface and in the cross section were successfully produced with a layer-by-layer approach achieving good reproducibility of the internal architecture and external shape. Changes in processing parameters were used to fabricate scaffolds with different architectural parameters in terms of average pore size in the xy-axes (from 190 to 297 µm) and in the z-axis (from 54 to 126 µm) and porosity (in the range of 20%–60%). Based on the mechanical characterization, processing variations and hydroxyapatite loading have an influence on scaffold compression properties. Cell cultures, using a murine pre-osteoblast cell line, had good cell responses in terms of proliferation and osteoblastic differentiation. Thus, this technique appears to be an effective method for producing customized polymeric scaffolds for bone tissue engineering applications.

Multifunctional polymeric microfibers with prolonged drug delivery and structural support capabilities

The strength and stability of hybrid fiber delivery systems, ones that perform a mechanical function and simultaneously deliver drug, are critical in the design of surgically implantable constructs. We report the fabrication of drug-eluting microfibers where drug loading and processing conditions alone increase microfiber strength and stability partially due to solvent-induced crystallization. Poly(L-lactic acid) microfibers of 64±7 μm diameter were wet spun by phase inversion. Encapsulation of a model hydrophobic anti-inflammatory drug, dexamethasone, at high loading provided stability to microfibers which maintained linear cumulative release kinetics up to 8 weeks in vitro. In our wet spinning process, all microfibers had increased crystallinity (13-17%) in comparison to unprocessed polymer without any mechanical stretching. Moreover, microfibers with the highest drug loading retained 97% of initial tensile strength and were statistically stronger than all other microfiber formulations, including control fibers without drug. Results indicate that the encapsulation of small hydrophobic molecules (<400 Da) may increase the mechanical integrity of microfilaments whose crystallinity is also increased as a result of the process. Multifunctional drug-eluting microfibers can provide an exciting new opportunity to design novel biomaterials with mechanical stability and controlled release of a variety of therapeutics with micron-scale accuracy.