Modeling of melt electrospinning for semi-crystalline polymers

Facile Adaptation of a Fused Deposition Modeling 3D Printer to Motionless Printing through Programmable Electric Relay: Discretized Modeling and Experiments

In this study, a fused deposition modeling 3D printer is modified into a motionless printer, which has the potential to print patterns in a noiseless manner possibly with improved resolution and in less delay time by eliminating the movement of nozzle or collector. In this motionless 3D printer, both nozzle and collector are fixed, whereas the extruded polymer melt is driven by high-voltage switching points on the collector. By this approach, simple 3D patterns such as multilayer circles, squares, and walls have been printed using two polymer melts with different rheological properties, high-temperature polylactic acid and acrylonitrile butadiene styrene. Furthermore, a discretized, nonisothermal bead and spring model is developed to probe printing patterns. The effect of parameters, such as number of conducting points, switching time, voltage and material properties on the accuracy of the printed simple 3D patterns, are thoroughly studied, and we demonstrated that various fiber collection patterns obtained from the experiments are favorably compared with the simulation results.

Planar or Biaxial Stretching of Poly(ethylene terephthalate) Fiber Webs Prepared by Laser-Electrospinning

In this work, laser-heated electrospinning (LES) process using carbon dioxide laser was explored as an eco-friendly method for producing ultrafine fibers. To enhance the thinning of fibers and the formation of fiber structure, planar or equibiaxial stretching and subsequent annealing processes were applied to poly(ethylene terephthalate) (PET) fiber webs prepared by LES. The structure and properties of the obtained webs were investigated. Ultrafine fiber webs with an average diameter of approximately 1 μm and a coefficient of variation of 20–25% were obtained when the stretch ratios in the MD (machine direction) × TD (transverse direction) were 3 × 1 and 3 × 3 for the planar and equibiaxial stretching, respectively. In the wide-angle X-ray diffraction analysis of the web samples, preferential orientation of crystalline c-axis were confirmed along the MD for planar stretching and only along the web plane for equibiaxial stretching, which was in contrast to the stretching of film samples, where additional preferential orientation of benzene ring along the film plane proceeded. The results obtained suggest that PET fiber webs fabricated through LES and subsequent planar or biaxial stretching processes have potential for a wide variety of applications, such as packaging and battery separator materials.

Bioinspired bimodal micro-nanofibrous scaffolds promote the tenogenic differentiation of tendon stem/progenitor cells for achilles tendon regeneration

Poor tendon repair remains a clinical problem due to the difficulties in replicating the complex multiscale hierarchical structure of native tendons. In this work, a bioinspired fibrous scaffold with bimodal micro-nanofibers and a teno-inductive aligned topography was developed to replicate microscale collagen fibers and nanoscale collagen fibrils that compose native tendons. The results showed indicated that the combination of micro- and nanofibers enhanced the mechanical properties. Furthermore, their biological performance was assessed using tendon stem/progenitor cells (TSPCs). Micro-nanofibers induced a higher cell aspect ratio and enhanced the tenogenic differentiation of TSPCs compared to micro- and nanocontrols. Interestingly, it was observed that scaffold nanotopography and microstructures promoted tenogenesis via activating the TGF-β/Smad2/3-mediated signaling pathway. The in situ implantation study confirmed that micro-nanofibrous scaffolds promoted the structural and mechanical properties of the regenerated Achilles tendon. Overall, our study shows that the bimodal micro-nanofibrous scaffold developed here presents a promising potential to improve the outcomes of tendon tissue engineering.

Melt Electrospinning of PET and Composite PET-Aerogel Fibers: An Experimental and Modeling Study

Increasingly advanced applications of polymer fibers are driving the demand for new, high-performance fiber types. One way to produce polymer fibers is by electrospinning from polymer solutions and melts. Polymer melt electrospinning produces fibers with small diameters through solvent-free processing and has applications within different fields, ranging from textile and construction, to the biotech and pharmaceutical industries. Modeling of the electrospinning process has been mainly limited to simulations of geometry-dependent electric field distributions. The associated large change in viscosity upon fiber formation and elongation is a key issue governing the electrospinning process, apart from other environmental factors. This paper investigates the melt electrospinning of aerogel-containing fibers and proposes a logistic viscosity model approach with parametric ramping in a finite element method (FEM) simulation. The formation of melt electrospun fibers is studied with regard to the spinning temperature and the distance to the collector. The formation of PET-Aerogel composite fibers by pneumatic transport is demonstrated, and the critical parameter is found to be the temperature of the gas phase. The experimental results form the basis for the electrospinning model, which is shown to reproduce the trend for the fiber diameter, both for polymer as well as polymer-aerogel composites.

Melt Electrospinning of Polymers: Blends, Nanocomposites, Additives and Applications

Melt electrospinning has been developed in the last decade as an eco-friendly and solvent-free process to fill the gap between the advantages of solution electrospinning and the need of a cost-effective technique for industrial applications. Although the benefits of using melt electrospinning compared to solution electrospinning are impressive, there are still challenges that should be solved. These mainly concern to the improvement of polymer melt processability with reduction of polymer degradation and enhancement of fiber stability; and the achievement of a good control over the fiber size and especially for the production of large scale ultrafine fibers. This review is focused in the last research works discussing the different melt processing techniques, the most significant melt processing parameters, the incorporation of different additives (e.g., viscosity and conductivity modifiers), the development of polymer blends and nanocomposites, the new potential applications and the use of drug-loaded melt electrospun scaffolds for biomedical applications.

Structure and Properties of Poly(ethylene terephthalate) Fiber Webs Prepared via Laser-Electrospinning and Subsequent Annealing Processes

Melt-electrospinning is an eco-friendly method for producing ultra-fine fibers without using any solvent. We prepared webs of poly(ethylene terephthalate) (PET) through melt-electrospinning using CO₂ laser irradiation for heating. The PET webs comprised ultra-fine fibers of uniform diameter (average fiber diameter = 1.66 μm, coefficient of variation = 19%). The co-existence of fibers with high and low molecular orientation was confirmed through birefringence measurements. Although the level of high orientation corresponded to that of commercial highly oriented yarn, crystalline diffraction was not observed in the wide-angle X-ray diffraction (WAXD) analysis of the webs. The crystallinity of the webs was estimated using differential scanning calorimetry (DSC). The fibers with higher birefringence did not exhibit any cold crystallization peak. After annealing the web at 116 °C for 5 min, a further increase in the birefringence of the fibers with higher orientation was observed. The WAXD results revealed that the annealed webs showed crystalline diffraction peaks with the orientation of the c-axis along the fiber axis. In summary, the formation of fibers with a unique non-crystalline structure with extremely high orientation was confirmed.

Melt Electrospinning Designs for Nanofiber Fabrication for Different Applications

Nanofibers have been attracting growing attention owing to their outstanding physicochemical and structural properties as well as diverse and intriguing applications. Electrospinning has been known as a simple, flexible, and multipurpose technique for the fabrication of submicro scale fibers. Throughout the last two decades, numerous investigations have focused on the employment of electrospinning techniques to improve the characteristics of fabricated fibers. This review highlights the state of the art of melt electrospinning and clarifies the major categories based on multitemperature control, gas assist, laser melt, coaxial, and needleless designs. In addition, we represent the effect of melt electrospinning process parameters on the properties of produced fibers. Finally, this review summarizes the challenges and obstacles connected to the melt electrospinning technique.

Current state of fabrication technologies and materials for bone tissue engineering

A range of traditional and free-form fabrication technologies have been investigated and, in numerous occasions, commercialized for use in the field of regenerative tissue engineering (TE). The demand for technologies capable of treating bone defects inherently difficult to repair has been on the rise. This quest, accompanied by the advent of functionally tailored, biocompatible, and biodegradable materials, has garnered an enormous research interest in bone TE. As a result, different materials and fabrication methods have been investigated towards this end, leading to a deeper understanding of the geometrical, mechanical and biological requirements associated with bone scaffolds. As our understanding of the scaffold requirements expands, so do the capability requirements of the fabrication processes. The goal of this review is to provide a broad examination of existing scaffold fabrication processes and highlight future trends in their development. To appreciate the clinical requirements of bone scaffolds, a brief review of the biological process by which bone regenerates itself is presented first. This is followed by a summary and comparisons of commonly used implant techniques to highlight the advantages of TE-based approaches over traditional grafting methods. A detailed discussion on the clinical and mechanical requirements of bone scaffolds then follows. The remainder of the manuscript is dedicated to current scaffold fabrication methods, their unique capabilities and perceived shortcomings. The range of biomaterials employed in each fabrication method is summarized. Selected traditional and non-traditional fabrication methods are discussed with a highlight on their future potential from the authors' perspective. This study is motivated by the rapidly growing demand for effective scaffold fabrication processes capable of economically producing constructs with intricate and precisely controlled internal and external architectures. STATEMENT OF SIGNIFICANCE: The manuscript summarizes the current state of fabrication technologies and materials used for creating scaffolds in bone tissue engineering applications. A comprehensive analysis of different fabrication methods (traditional and free-form) were summarized in this review paper, with emphasis on recent developments in the field. The fabrication techniques suitable for creating scaffolds for tissue engineering was particularly targeted and their use in bone tissue engineering were articulated. Along with the fabrication techniques, we emphasized the choice of materials in these processes. Considering the limitations of each process, we highlighted the materials and the material properties critical in that particular process and provided a brief rational for the choice of the materials. The functional performance for bone tissue engineering are summarized for different fabrication processes and the choice of biomaterials. Finally, we provide a perspective on the future of the field, highlighting the knowledge gaps and promising avenues in pursuit of effective scaffolds for bone tissue engineering. This extensive review of the field will provide research community with a reference source for current approaches to scaffold preparation. We hope to encourage the researchers to generate next generation biomaterials to be used in these fabrication processes. By providing both advantages and disadvantage of each fabrication method in detail, new fabrication techniques might be devised that will overcome the limitations of the current approaches. These studies should facilitate the efforts of researchers interested in generating ideal scaffolds, and should have applications beyond the repair of bone tissue.

Preparation of Polypropylene Micro and Nanofibers by Electrostatic-Assisted Melt Blown and Their Application

In this paper, a novel electrostatic-assisted melt blown process was reported to produce polypropylene (PP) microfibers with a diameter as fine as 600 nm. The morphology, web structure, pore size distribution, filtration efficiency, and the stress and strain behavior of the PP nonwoven fabric thus prepared were characterized. By introducing an electrostatic field into the conventional melt-blown apparatus, the average diameter of the melt-blown fibers was reduced from 1.69 to 0.96 μm with the experimental setup, and the distribution of fiber diameters was narrower, which resulted in a filter medium with smaller average pore size and improved filtration efficiency. The polymer microfibers prepared by this electrostatic-assisted melt blown method may be adapted in a continuous melt blown process for the production of filtration media used in air filters, dust masks, and so on.

Melt electrospinning of daunorubicin hydrochloride-loaded poly (ε-caprolactone) fibrous membrane for tumor therapy

Daunorubicin hydrochloride is a cell-cycle non-specific antitumor drug with a high therapeutic effect. The present study outlines the fabrication of daunorubicin hydrochloride-loaded poly (ε-caprolactone) (PCL) fibrous membranes by melt electrospinning for potential application in localized tumor therapy. The diameters of the drug-loaded fibers prepared with varying concentrations of daunorubicin hydrochloride (1, 5, and 10 wt%) were 2.48 ± 1.25, 2.51 ± 0.78, and 2.49 ± 1.58 μm, respectively. Fluorescence images indicated that the hydrophobic drug was dispersed in the hydrophilic PCL fibers in their aggregated state. The drug release profiles of the drug-loaded PCL melt electrospun fibrous membranes were approximately linear, with slow release rates and long-term release periods, and no observed burst release. The MTT assay was used to examine the cytotoxic effect of the released daunorubicin hydrochloride on HeLa and glioma cells (U87) in vitro. The inhibition ratios of HeLa and glioma cells following treatment with membranes prepared with 1, 5, and 10 wt% daunorubicin hydrochloride were 62.69%, 76.12%, and 85.07% and 62.50%, 77.27%, and 84.66%, respectively. Therefore, PCL melt electrospun fibrous membranes loaded with daunorubicin hydrochloride may be used in the local administration of oncotherapy.

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Daunorubicin hydrochloride-loaded PCL fibrous membranes were prepared by melt electrospinning.

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Hydrophilic drug was dispersed in the PCL melt electrospun fiber in the form of aggregation.

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Daunorubicin hydrochloride-loaded PCL fibrous membranes showed low drug release rate and long-term release periods.

Processing and surface modification of polymer nanofibers for biological scaffolds: a review

Polymeric fibrous constructs possess high surface area-to-volume ratios when compared with solid substrates and are quite commonly used as tissue engineering and cell growth scaffolds. An overview of important design and material considerations for fibrous scaffolds as well as an outline of both established and emerging solution- and melt-based fabrication techniques is provided. Innovative post-process surface modification avenues using "click" chemistry with both single and dual active cues as well as gradient cues, which maintain the fibrous structure are described. By combining process parameters with post-process surface modification, researchers have been able to selectively tune cellular response after seeding and culturing on fibrous constructs.

Recent advances in melt electrospinning

With the emergence of one-dimensional (1D) functional nanomaterials and their promising applications, electrospinning (e-spinning) technology and electrospun (e-spun) ultrathin fibers have been widely explored.

Fabrication of microfibrous and nano-/microfibrous scaffolds: melt and hybrid electrospinning and surface modification of poly(L-lactic acid) with plasticizer

Biodegradable poly(L-lactic acid) (PLA) fibrous scaffolds were prepared by electrospinning from a PLA melt containing poly(ethylene glycol) (PEG) as a plasticizer to obtain thinner fibers. The effects of PEG on the melt electrospinning of PLA were examined in terms of the melt viscosity and fiber diameter. Among the parameters, the content of PEG had a more significant effect on the average fiber diameter and its distribution than those of the spinning temperature. Furthermore, nano-/microfibrous silk fibroin (SF)/PLA and PLA/PLA composite scaffolds were fabricated by hybrid electrospinning, which involved a combination of solution electrospinning and melt electrospinning. The SF/PLA (20/80) scaffolds consisted of a randomly oriented structure of PLA microfibers (average fiber diameter = 8.9 µm) and SF nanofibers (average fiber diameter = 820 nm). The PLA nano-/microfiber (20/80) scaffolds were found to have similar pore parameters to the PLA microfiber scaffolds. The PLA scaffolds were treated with plasma in the presence of either oxygen or ammonia gas to modify the surface of the fibers. This approach of controlling the surface properties and diameter of fibers could be useful in the design and tailoring of novel scaffolds for tissue engineering.

Polymeric nanofibers in tissue engineering

Polymeric nanofibers can be produced using methods such as electrospinning, phase separation, and self-assembly, and the fiber composition, diameter, alignment, degradation, and mechanical properties can be tailored to the intended application. Nanofibers possess unique advantages for tissue engineering. The small diameter closely matches that of extracellular matrix fibers, and the relatively large surface area is beneficial for cell attachment and bioactive factor loading. This review will update the reader on the aspects of nanofiber fabrication and characterization important to tissue engineering, including control of porous structure, cell infiltration, and fiber degradation. Bioactive factor loading will be discussed with specific relevance to tissue engineering. Finally, applications of polymeric nanofibers in the fields of bone, cartilage, ligament and tendon, cardiovascular, and neural tissue engineering will be reviewed.

Melt electrospinning

Melt electrospinning is relatively under-investigated compared to solution electrospinning but provides opportunities in numerous areas, in which solvent accumulation or toxicity are a concern. These applications are diverse, and provide a broad set of challenges to researchers involved in electrospinning. In this context, melt electrospinning provides an alternative approach that bypasses some challenges to solution electrospinning, while bringing new issues to the forefront, such as the thermal stability of polymers. This Focus Review describes the literature on melt electrospinning, as well as highlighting areas where both melt and solution are combined, and potentially merge together in the future.