Toward a Tunable Fibrous Scaffold: Structural Development during Uniaxial Drawing of Coextruded Poly(ε-caprolactone) Fibers

PET-RAFT to expand the surface-modification chemistry of melt coextruded nanofibers

Polymeric nanofibers have been widely used as scaffolds for tissue engineering, drug delivery, and filtration applications, among many others. This work describes new methods to modify chemically-inert fibers using PET-RAFT.

Tunable Tensile Properties of Polypropylene and Polyethylene Terephthalate Fibrillar Blends through Micro-/Nanolayered Extrusion Technology

Fiber-reinforcement is a well-established technique to enhance the tensile properties of polymer composites, which is achieved via changing the reinforcing material concentration and orientation. However, the conventional method can be costly and may lead to poor compatibility issues. To overcome these challenges, we demonstrate the use of micro-/nanolayer (MNL) extrusion technology to tune the mechanical properties of polypropylene (PP)/polyethylene terephthalate (PET) fibrillar blends. PET nanofibers-in-PP microfiber composites, with 3, 7, and 15 wt.% PET, are first prepared using a spunbond system to induce high aspect-ratio PET nanofibers. The PP/PET fibers are then reprocessed in an MNL extrusion system and subjected to shear and extensional flow fields in the channels of the uniquely designed layer multipliers. Increasing the mass flow rate and number of multipliers is shown to orient the PET nanofibers along the machine direction (MD), as confirmed via scanning electron microscopy. Tensile tests reveal that up to a 45% and 46% enhancement in elastic modulus and yield strength are achieved owing to the highly aligned PET nanofibers along the MD under strongest processing conditions. Overall, the range of tensile properties obtained using MNL extrusion implies that the properties of fiber-reinforced composites can be further tuned by employing this processing technique.

Enhancement of the Mechanical Properties of Hydrogels with Continuous Fibrous Reinforcement

Reinforcing mechanically weak hydrogels with fibers is a promising route to obtain strong and tough materials for biomedical applications while retaining a favorable cell environment. The resulting hierarchical structure recreates structural elements of natural tissues such as articular cartilage, with fiber diameters ranging from the nano- to microscale. Through control of properties such as the fiber diameter, orientation, and porosity, it is possible to design materials which display the nonlinear, synergistic mechanical behavior observed in natural tissues. In order to fully exploit these advantages, it is necessary to understand the structure-property relationships in fiber-reinforced hydrogels. However, there are currently limited models which capture their complex mechanical properties. The majority of reported fiber-reinforced hydrogels contain fibers obtained by electrospinning, which allows for limited spatial control over the fiber scaffold and limits the scope for systematic mechanical testing studies. Nevertheless, new manufacturing techniques such as melt electrowriting and bioprinting have emerged, which allow for increased control over fiber deposition and the potential for future investigations on the effect of specific structural features on mechanical properties. In this review, we therefore explore the mechanics of fiber-reinforced hydrogels, and the evolution of their design and manufacture from replicating specific features of biological tissues to more complex structures, by taking advantage of design principles from both tough hydrogels and fiber-reinforced composites. By highlighting the overlap between these fields, it is possible to identify the remaining challenges and opportunities for the development of effective biomedical devices.

Structural insights into semicrystalline states of electrospun nanofibers: a multiscale analytical approach

A dedicated nanofiber design for applications in the biomedical domain is based on the understanding of nanofiber structures. The structure of electrospun nanofibers strongly influences their properties and functionalities. In polymeric nanofibers X-ray scattering and diffraction methods, i.e. SAXS and WAXD, are capable of decoding their structural insights from about 100 nm down to the Angström scale. Here, we present a comprehensive X-ray scattering and diffraction based study and introduce new data analysis approaches to unveil detailed structural features in electrospun poly(vinylidene fluoride-co-hexafluoropropylene) (PVDFhfp) nanofiber membranes. Particular emphasis was placed on anisotropic morphologies being developed during the nanofiber fabrication process. Global analysis was performed on SAXS data to derive the nanofibrillar structure of repeating lamella crystalline domains with average dimensions of 12.5 nm thickness and 7.8 nm spacing along with associated tie-molecules. The varying surface roughness of the nanofiber was evaluated by extracting the Porod exponent in parallel and perpendicular direction to the nanofiber axis, which was further validated by Atomic Force Microscopy. Additionally, the presence of a mixture of the monoclinic alpha and the orthorhombic beta PVDFhfp phases both exhibiting about 6% larger unit cells compared to the corresponding pure PVDF phases was derived from WAXD. The current study shows a generic approach in detailed understanding of internal structures and surface morphology for nanofibers. This forms the basis for targeted structure and morphology steering and the respective controlling during the fabrication process with the aim to engineer nanofibers for different biomedical applications with specific requirements.

Bioinspired Concentric-Cylindrical Multilayered Scaffolds with Controllable Architectures: Facile Preparation and Biological Applications

Multilayered objects are the most important and interesting structures in nature, exhibiting multiple functionalities. Inspired by the excellent structural-functional characteristics of nature creatures, concentric-cylindrical multilayered scaffolds were prepared by a combination of melt extrusion and leaching, in which well-defined alternating microlayer/gap is assembled. Furthermore, the macroscopic shape, internal structure, and surface topography of such a multilayered scaffold can be elaborately prepared by a simple physical process. The whole process has low cost, is efficient, and is environmentally friendly. Furthermore, such multilayered scaffolds show some interesting applications, e.g., lipophilic/hydrophilic drugs delivery and cell self-seeding. Considering the facile preparation process and versatile applications, this study will open up a new pathway to fabricate scaffolds with controllable architectures and expand their biodegradable polymer applications.

Nanolayer coextrusion: An efficient and environmentally friendly micro/nanofiber fabrication technique

Researchers have developed many types of nanoscale materials with different properties. Among them, nanofibers have recently attracted increasing interest and attention due to their functional versatility and potential applications in diverse industries, including tapes, filtration, energy generation, and biomedical technologies. Nanolayer coextrusion, a novel polymer melt fiber processing technology, has gradually received attention due to its environmental friendliness, efficiency, simplicity and ability to be mass-produced. Compared with conventional techniques, nanolayer coextruded non-woven nanofibrous mats offer advantages such as a tunable fiber diameter, high porosity, high surface area to volume ratio, and the potential to manufacture composite nanofibers with different components to achieve desired structures and properties. Dozens of thermoplastic polymers have been coextruded for various applications, and the variety of polymers has gradually continued to increase. This review presents an overview of the nanolayer coextrusion technique and its promising advantages and potential applications. We discuss nanolayer coextrusion theory and the parameters (polymer and processing) that significantly affect the fiber morphology and properties. We focus on varied applications of nanolayer coextruded fibers in different fields and conclude by describing the future potential of this novel technology.

Programming shape and tailoring transport: advancing hygromorphic bilayers with aligned nanofibers

Natural systems utilize nanofiber architectures to guide water transport, tune mechanical properties, and actuate in response to their environment. In order to harness these properties, a hygromorphic bilayer composite comprised of a self-assembled fiber network and an aligned electrospun fiber network was fabricated. Molecular gel self-assembly was utilized to increase hydrophobicity and strength in one layer, while aligned electrospun poly(vinyl alcohol) (PVA) nanofibers increased the rate of hydration and facilitated tunable actuation in the other. Interfacing these two fiber networks in a poly(ethylene oxide-co-epichlorohydrin) (EO-EPI) matrix led to hydration-driven actuation with tunable curvature. Specifically, variations in fiber alignment were achieved by cutting at 0, 90, and 45 degree angles in relation to the length edge of the composite. Along with the ability to program the natural curvature, the utilization of aligned nanofibers increased water transport compared to random nanofiber systems, resulting in a reduction in response time from 20+ minutes to 2-3 minutes.

Polymeric Nanofiber/Antifungal Formulations Using a Novel Co-extrusion Approach

We report the successful implementation of a novel melt co-extrusion process to fabricate ca. 1 μm diameter fibers of poly(caprolactone) (PCL) containing the antifungal compound clotrimazole in concentrations between 4 and 8 wt%. The process involves co-extrusion of a clotrimazole-loaded PCL along with poly(ethylene oxide) (PEO) as a co-feed, with subsequent removal of PEO to isolate PCL-clotrimazole fibers. In vitro tests of the clotrimazole-containing fibers against the fungus Aspergillus fumigatus, Candida albicans, and Trichophyton mentagrophytes strains demonstrated good antifungal activity which was maintained for more than 3 weeks. An in vivo study using a mouse model showed the lowest tissue fungal burden for PCL-clotrimazole when compared to a PCL-only patch and untreated controls. Comparative studies were conducted with clotrimazole-containing PCL fibers fabricated by electrospinning. Our data showed that the co-extruded, clotrimazole-containing fibers maintain activity for longer times vs. electrospun samples. This, coupled with the much higher throughput of the co-extrusion process vs. electrospinning, renders this new approach very attractive for the fabrication of drug-releasing polymer fibers.

Drawing in poly(ε-caprolactone) fibers: tuning mechanics, fiber dimensions and surface-modification density

This work describes the complex interplay between mechanical manipulation of coextruded fibers and the resulting photochemical yield of surface modification.

Relationships between mechanical properties and drug release from electrospun fibers of PCL and PLGA blends

Electrospun nanofibers have the potential to achieve high drug loading and the ability to sustain drug release. Mechanical properties of the drug-incorporated fibers suggest the importance of drug-polymer interactions. In this study, we investigated the mechanical properties of electrospun polycaprolactone (PCL) and poly (D,L-lactic-co-glycolic) acid (PLGA) fibers at various blend ratios in the presence and absence of a small molecule hydrophilic drug, tenofovir (TFV). Young׳s modulus of the blend fibers showed dependence on PLGA content and the addition of the drug. At a PCL/PLGA (20/80) composition, Young׳s modulus and tensile strength were independent of drug loading up to 40wt% due to offsetting effects from drug-polymer interactions. In vitro drug release studies suggested that release of TFV significantly decreased fiber mechanical properties. In addition, mechanically stretched fibers displayed a faster release rate as compared to the non-stretched fibers. Finally, drug partition in the blend fibers was estimated using a mechanical model and then experimentally confirmed with a composite of individually stacked fiber meshes. This work provides scientific understanding on the dependence of drug release and drug loading on the mechanical properties of drug-eluting fibers.

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.

Protein and Bacterial Antifouling Behavior of Melt-Coextruded Nanofiber Mats

Antifouling surfaces are important for biomedical devices to prevent secondary infections and mitigate the effects of the foreign body response. Herein, we describe melt-coextruded poly(ε-caprolactone) (PCL) nanofiber mats grafted with antifouling polymers. Nonwoven PCL fiber mats are produced using a multilayered melt coextrusion process followed by high-pressure hydroentanglement to yield porous patches. The resulting fiber mats show submicrometer cross-sectional fiber dimensions and yield pore sizes that were nearly uniform, with a mean pore size of 1.6 ± 0.9 μm. Several antifouling polymers, including hydrophilic, zwitterionic, and amphipathic molecules, are grafted to the surface of the mats using a two-step procedure that includes photochemistry followed by the copper-catalyzed azide-alkyne cycloaddition reaction. Fiber mats are evaluated using separate adsorption tests for serum proteins and E. coli. The results indicate that poly(oligo(ethylene glycol) methyl ether methacrylate)-co-(trifluoroethyl methacrylate) (poly(OEGMEMA-co-TFEMA)) grafted mats exhibit approximately 85% less protein adhesion and 97% less E. coli adsorption when compared to unmodified PCL fibermats. In dynamic antifouling testing, the amphiphilic fluorous polymer surface shows the highest flux and highest rejection value of foulants. The work presented within has implications on the high-throughput production of antifouling microporous patches for medical applications.