Wet-Spinning of Regenerated Silk Fiber from Aqueous Silk Fibroin Solution: Discussion of Spinning Parameters

Hierarchical design of silkworm silk for functional composites

Silk-reinforced composites (SRCs) manifest the unique properties of silkworm silk fibers, offering enhanced mechanical strength, biocompatibility, and biodegradability. These composites present an eco-friendly alternative to conventional synthetic materials, with applications expanding beyond biomedical engineering, flexible electronics, and environmental filtration. This review explores the diverse forms of silkworm silk fibers including fabrics, long fibers, and nanofibrils, for functional composites. It highlights advancements in composite design and processing techniques that allow precise engineering of mechanical and functional performance. Despite substantial progress, challenges remain in making optimally functionalized SRCs with multi-faceted performance and understanding the mechanics for reverse-design of SRCs. Future research should focus on the unique sustainable, biodegradable and biocompatible advantages and embrace advanced processing technology, as well as artificial intelligence-assisted material design to exploit the full potential of SRCs. This review on SRCs will offer a foundation for future advancements in multifunctional and high-performance silk-based composites.

Recreating Silk's Fibrillar Nanostructure by Spinning Solubilized, Undegummed Silk

The remarkable toughness (>70 MJ m-3) of silkworm silk is largely attributed to its hierarchically arranged nanofibrillar nanostructure. Recreating such tough fibers through artificial spinning is often challenging, in part because degummed, dissolved silk is drastically different to the unspun native feedstock found in the spinning gland. The present work demonstrates a method to dissolve silk without degumming to produce a solution containing undegraded fibroin and sericin. This solution exhibits liquid-liquid phase separation above 10% (wt/wt), a behavior observed in the silk gland but not in degummed silk solutions to date. This partitioning enhances the stability of the undegummed solution, delaying gelation two-fold compared with degummed silk at the same concentration. When spun under identical conditions, undegummed solutions produces fibers 8× stronger and 218× tougher than degummed silk feedstocks. Through ultrasonication, undegummed wet spun fibers are seen to possess hierarchical structure of densely packed ≈20 nm nanofibrils, similar to native silks, although completely absent from fibers wet-spun from degummed silk solutions. This work demonstrates that the preservation of molecular weight, presence of sericin and stimulation of liquid-liquid phase separation underpin a new pathway to recreate a hierarchical fiber with structures akin to native silk.

Designing Silk Biomaterials toward Better Future Healthcare: The Development and Application of Silk-Based Implantable Electronic Devices in Clinical Diagnosis and Therapy

Implantable medical electronic devices (IMEDs) have attracted great attention and shown versatility for solving clinical problems ranging from real-time monitoring of physiological/ pathological states to electrical stimulation therapy and from monitoring brain cell activity to deep brain stimulation. The ongoing challenge is to select appropriate materials in target device configuration for biomedical applications. Currently, silk-based biomaterials have been developed for the design of diagnostic and therapeutic electronic devices due to their excellent properties and abundant active sites in the structure. Herein, the aim is to summarize the structural characteristics, physicochemical properties, and bioactivities of natural silk biomaterials as well as their derived materials, with a particular focus on the silk-based implantable biomedical electronic devices, such as implantable devices for invasive brain-computer interfaces, neural recording, and in vivo electrostimulation. In addition, future opportunities and challenges are also envisioned, hoping to spark the interests of researchers in interdisciplinary fields such as biomaterials, clinical medicine, and electronics.

Solution Blow Spinning: An Emerging Nanomaterials-Based Wound-Care Technology

Application of one-dimensional nanofibers have witnessed exponential growth over the past few decades and are still emerging with their excellent physicochemical and electrical properties. The driving force behind this intriguing transition lies in their unique high surface-to-volume ratio, ubiquitous nanodomains, improved tensile strength, and flexibility to incorporate deliberate functionalities required for specific and advanced applications. Besides numerous benefits, nanomaterials may adversely interact with biological tissues and potentially be cytotoxic and carcinogenic. However, precisely engineered design can outperform the risk with myriad benefits. Wound care technologies are evolving, and products involved in wound care management have a yearly market value of $15-22 billion. Solution blow spinning (SBS) is a facile technique to synthesize biocompatible nanofibers with scalable processing variables for multidirectional biomedical applications. SBS is feasible for a wide range of thermoplastic polymers and nanomaterials to fabricate nanocomposites. This review will focus on the relevance of SBS technology for wound care, including dressings, drug delivery, tissue engineering scaffolds, and sensors.

Comparison of Chondrocyte Behaviors Between Silk Microfibers and Polycaprolactone Microfibers in Tissue Engineering and Regenerative Medicine Applications

Silk and polycaprolactone (PCL), derived from natural and synthetic sources, respectively, are suture materials commonly used in surgery. Beyond their application in sutures, they are also compelling subjects in regenerative medicine and tissue engineering. This study evaluated the effects of degummed silk microfibers compared to electrospun PCL microfibers of a similar diameter on chondrocyte behavior. The two types of microfibers were analyzed using scanning electron microscopy (SEM), real-time PCR, Western blotting, and DMMB analysis. The results demonstrated that the silk microfibers exhibited a higher proliferative cell rate over time compared to the PCL microfibers. Additionally, the expression of chondrogenic phenotypes was significantly upregulated, while the marker for hypertrophic chondrocytes-type X collagen-was downregulated in cell-laden silk microfibers compared to cell-laden PCL microfibers. These findings suggest that natural degummed silk microfibers may be a viable option for repairing damaged cartilage in the future of orthopedic surgery and bioengineering.

Microstructured silk fiber scaffolds with enhanced stretchability

Despite extensive research, current methods for creating three-dimensional (3D) silk fibroin (SF) scaffolds lack control over molecular rearrangement, particularly in the formation of β-sheet nanocrystals that severely embrittle SF, as well as hierarchical fiber organization at both micro- and macroscale. Here, we introduce a fabrication process based on electrowriting of aqueous SF solutions followed by post-processing using an aqueous solution of sodium dihydrogen phosphate (NaH2PO4). This approach enables gelation of SF chains via controlled β-sheet formation and partial conservation of compliant random coil structures. Moreover, this process allows for precise architecture control in microfiber scaffolds, enabling the creation of 3D flat and tubular macro-geometries with square-based and crosshatch microarchitectures, featuring inter-fiber distances of 400 μm and ∼97% open porosity. Remarkably, the crosslinked printed structures demonstrated a balanced coexistence of β-sheet and random coil conformations, which is uncommon for organic solvent-based crosslinking methods. This synergy of printing and post-processing yielded stable scaffolds with high compliance (modulus = 0.5-15 MPa) and the ability to support elastic cyclic loading up to 20% deformation. Furthermore, the printed constructs supported in vitro adherence and growth of human renal epithelial and endothelial cells with viability above 95%. These cells formed homogeneous monolayers that aligned with the fiber direction and deposited type-IV collagen as a specific marker of healthy extracellular matrix, indicating that both cell types attach, proliferate, and organize their own microenvironment within the SF scaffolds. These findings represent a significant development in fabricating organized stable SF scaffolds with unique microfiber structures and mechanical and biological properties that make them highly promising for tissue engineering applications.

Regenerated Fiber's Ideal Target: Comparable to Natural Fiber

The toughness of silk naturally obtained from spiders and silkworms exceeds that of all other natural and man-made fibers. These insects transform aqueous protein feedstocks into mechanically specialized materials, which represents an engineering phenomenon that has developed over millions of years of natural evolution. Silkworms have become a new research hotspot due to the difficulties in collecting spider silk and other challenges. According to continuous research on the natural spinning process of the silkworm, it is possible to divide the main aspects of bionic spinning into two main segments: the solvent and behavior. This work focuses on the various methods currently used for the spinning of artificial silk fibers to replicate natural silk fibers, providing new insights based on changes in the fiber properties and production processes over time.

Pulling and analyzing silk fibers from aqueous solution using a robotic device

Spiders, silkworms, and many other animals can spin silk with exceptional properties. However, artificially spun fibers often fall short of their natural counterparts partly due sub-optimal production methods. A variety of methods, such as wet-, dry-, and biomimetic spinning have been used. The methods are based on extrusion, whereas natural spinning also involves pulling. Another shortcoming is that there is a lack feedback control during extension. Here we demonstrate a robotic fiber pulling device that enables controlled pulling of silk fibers and in situ measurement of extensional forces during the pulling and tensile testing of the pulled fibers. The pulling device was used to study two types of silk-one recombinant spider silk (a structural variant of ADF3) and one regenerated silk fibroin. Also, dextran-a branched polysaccharide-was used as a reference material for the procedure due to its straightforward preparation and storage. No post-treatments were applied. The pulled regenerated silk fibroin fibers achieved high tensile strength in comparison to similar extrusion-based methods. The mechanical properties of the recombinant spider silk fibers seemed to be affected by the liquid-liquid phase separation of the silk proteins.

Embedding Living Cells with a Mechanically Reinforced and Functionally Programmable Hydrogel Fiber Platform

Living materials represent a new frontier in functional material design, integrating synthetic biology tools to endow materials with programmable, dynamic, and life-like characteristics. However, a major challenge in creating living materials is balancing the tradeoff between structural stability, mechanical performance, and functional programmability. To address this challenge, a sheath-core living hydrogel fiber platform that synergistically integrates living bacteria with hydrogel fibers to achieve both functional diversity and structural and mechanical robustness is proposed. In the design, microfluidic spinning is used to produce hydrogel fiber, which offers advantages in both structural and functional designability due to their hierarchical porous architectures that can be tailored and their mechanical performance that can be enhanced through a variety of post-processing approaches. By introducing living bacteria, the platform is endowed with programmable functionality and life-like capabilities. This work reconstructs the genetic circuits of living bacteria to express chromoproteins and fluorescent proteins as two prototypes that enable the coloration of living fibers and sensing water pollutants by monitoring the amount of fluorescent protein expressed. Altogether, this study establishes a structure-property-function optimized living hydrogel fiber platform, providing a new tool for accelerating the practical applications of the emerging living material systems.

Natural spider silk nanofibrils produced by assembling molecules or disassembling fibers

Spider silk is biocompatible, biodegradable, and rivals some of the best synthetic materials in terms of strength and toughness. Despite extensive research, comprehensive experimental evidence of the formation and morphology of its internal structure is still limited and controversially discussed. Here, we report the complete mechanical decomposition of natural silk fibers from the golden silk orb-weaver Trichonephila clavipes into ≈10 nm-diameter nanofibrils, the material's apparent fundamental building blocks. Furthermore, we produced nanofibrils of virtually identical morphology by triggering an intrinsic self-assembly mechanism of the silk proteins. Independent physico-chemical fibrillation triggers were revealed, enabling fiber assembly from stored precursors "at-will". This knowledge furthers the understanding of this exceptional material's fundamentals, and ultimately, leads toward the realization of silk-based high-performance materials. STATEMENT OF SIGNIFICANCE: Spider silk is one of the strongest and toughest biomaterials, rivaling the best man-made materials. The origins of these traits are still under debate but are mostly attributed to the material's intriguing hierarchical structure. Here we fully disassembled spider silk into 10 nm-diameter nanofibrils for the first time and showed that nanofibrils of the same appearance can be produced via molecular self-assembly of spider silk proteins under certain conditions. This shows that nanofibrils are the key structural elements in silk and leads toward the production of high-performance future materials inspired by spider silk.

Highly stretchable porous regenerated silk fibroin film for enhanced wound healing

Silk fibroin (SF) has received interest in tissue engineering owing to its biocompatibility, biodegradability, and favorable mechanical properties. However, the complex preparation, brittleness, and lack of pores in the structure of the silk fibroin film limit its application. Herein, we show that facile dissolution of SF in aqueous phosphoric acid followed by regeneration in aqueous ammonium sulfate ((NH₄)₂SO₄) could afford highly stretchable films with nano-pores formed in the nonsolvent-induced phase separation process. The named phase separation, which determines the morphology and mechanical properties of the regeneration silk fibroin (RSF) films, is highly dependent on the (NH₄)₂SO₄ concentration as well as the initial concentration of the SF solution. Therefore, the RSF films exhibit a tunable pore size ranging from 230 to 510 nm and excellent stretchability with tensile strain up to 143 ± 16%. Most interestingly, the RSF films were shown to support the proliferation of human skin fibroblasts in vitro as well as speed up full-thickness skin wound healing in a rat model. This work establishes an easy and feasible method to access porous RSF membranes that can be used for wound dressing in clinical settings.

The Size Effect of Silver Nanoparticles on Reinforcing the Mechanical Properties of Regenerated Fibers

Regenerated silk fibroin (RSF), made from discarded silk cocoons, can be processed into regenerated silk fibers by a simple, inexpensive, and environmentally friendly wet-spinning process. However, the breaking strength and toughness of most RSF fibers are lower than those of natural silk. In this study, Ag nanoparticles (NPs) of different sizes were introduced into RSF to form RSF/AgNPs hybrid fibers by wet spinning. The effects of AgNPs of different sizes on the mechanical properties and structure of the hybrid fibers were investigated. The results demonstrated that the mechanical properties of hybrid fibers were significantly improved, especially the breaking strain, after the addition of four different sizes of AgNPs. With the reduction in AgNPs size (2-60 nm), the breaking strength and breaking strain of hybrid fibers tended to increase. The results showed that the hybrid fibers containing 2 nm AgNPs were remarkable, with excellent mechanical properties and toughness, and the breaking strain reached 138.27%, which was far greater than blank RSF fibers (15.02%) and even natural silk (about 21%). The S-FTIR and WAXD showed that, compared with the larger AgNPs, the smaller AgNPs contributed more to the formation of silk fibroin β-sheet and crystallinity, and reduced the β-crystallite size. This study is helpful to understand the relationship between the size of nanoparticles and the mechanical properties of hybrid fibers.

The mechanical behavior of silk-fibroin reinforced alginate hydrogel biocomposites - Toward functional tissue biomimetics

Soft tissues are constructed as fiber-reinforced composites consisting of structural mechanisms and unique mechanical behavior. Biomimetics of their mechanical behavior is currently a significant bioengineering challenge, emphasizing the need to replicate structural and mechanical mechanisms into novel biocomposite designs. Here we present a novel silk-based biocomposite laminate constructed from long natural silk and fibroin fibers embedded in an alginate hydrogel matrix. Controlling the mechanical features of these laminates were studied for different fiber volume fractions (VF) and orientations using unidirectional tensile tests. Three material systems were investigated having different fiber orientations: longitudinal (0°), transverse (90°), and cross-plied (0/90°). The general behavior of the biocomposite laminates was anisotropic hyperelastic with large deformations. Longitudinal fibroin laminates have shown a tensile modulus of 178.55 ± 14.46 MPa and tensile strength of 18.47 ± 2.01 MPa for 0.48 VF. With similar VF, cross-plied fibroin laminates demonstrated structural shielding ability, having a tensile modulus and tensile strength of 101.73 ± 8.04 MPa and 8.29 ± 1.63 MPa for only a third of the VF directed in the stretching direction. The stress-strain behavior was in a similar range to highly stiff native human soft tissues such as ligament and meniscus. These findings demonstrate the potential of the fibroin fiber-reinforced biocomposites to mimic the mechanics of tissues with a quantitatively controlled amount of fibers and designed spatial arrangement. This can lead to new solutions for the repair and replacement of damaged functional and highly stiff soft tissues.

Sources, Chemical Functionalization, and Commercial Applications of Nanocellulose and Nanocellulose-Based Composites: A Review

Nanocellulose is the most abundant material extracted from plants, animals, and bacteria. Nanocellulose is a cellulosic material with nano-scale dimensions and exists in the form of cellulose nanocrystals (CNC), bacterial nanocellulose (BNC), and nano-fibrillated cellulose (NFC). Owing to its high surface area, non-toxic nature, good mechanical properties, low thermal expansion, and high biodegradability, it is obtaining high attraction in the fields of electronics, paper making, packaging, and filtration, as well as the biomedical industry. To obtain the full potential of nanocellulose, it is chemically modified to alter the surface, resulting in improved properties. This review covers the nanocellulose background, their extraction methods, and possible chemical treatments that can enhance the properties of nanocellulose and its composites, as well as their applications in various fields.

Robust Assembly of Cross-Linked Protein Nanofibrils into Hierarchically Structured Microfibers

Natural, high-performance fibers generally have hierarchically organized nanosized building blocks. Inspired by this, whey protein nanofibrils (PNFs) are assembled into microfibers, using flow-focusing. By adding genipin as a nontoxic cross-linker to the PNF suspension before spinning, significantly improved mechanical properties of the final fiber are obtained. For curved PNFs, with a low content of cross-linker (2%) the fiber is almost 3 times stronger and 4 times stiffer than the fiber without a cross-linker. At higher content of genipin (10%), the elongation at break increases by a factor of 2 and the energy at break increases by a factor of 5. The cross-linking also enables the spinning of microfibers from long straight PNFs, which has not been achieved before. These microfibers have higher stiffness and strength but lower ductility and toughness than those made from curved PNFs. The fibers spun from the two classes of nanofibrils show clear morphological differences. The study demonstrates the production of protein-based microfibers with mechanical properties similar to natural protein-based fibers and provides insights about the role of the nanostructure in the assembly process.

Recent advances in bioprinting using silk protein-based bioinks

3D printing has experienced swift growth for biological applications in the field of regenerative medicine and tissue engineering. Essential features of bioprinting include determining the appropriate bioink, printing speed mechanics, and print resolution while also maintaining cytocompatibility. However, the scarcity of bioinks that provide printing and print properties and cell support remains a limitation. Silk Fibroin (SF) displays exceptional features and versatility for inks and shows the potential to print complex structures with tunable mechanical properties, degradation rates, and cytocompatibility. Here we summarize recent advances and needs with the use of SF protein from Bombyx mori silkworm as a bioink, including crosslinking methods for extrusion bioprinting using SF and the maintenance of cell viability during and post bioprinting. Additionally, we discuss how encapsulated cells within these SF-based 3D bioprinted constructs are differentiated into various lineages such as skin, cartilage, and bone to expedite tissue regeneration. We then shift the focus towards SF-based 3D printing applications, including magnetically decorated hydrogels, in situ bioprinting, and a next-generation 4D bioprinting approach. Future perspectives on improvements in printing strategies and the use of multicomponent bioinks to improve print fidelity are also discussed.

Formylation of Recombinant Spider Silk in Formic Acid and Wet Spinning Studied Using Nuclear Magnetic Resonance and Infrared Spectroscopies

We reported wet spinning of recombinant spider silk protein (RSSP) and formylation of RSSP in formic acid (FA). First, FA was selected as the spinning solvent and the detailed spinning condition was determined. Next, the mechanical property was compared between the RSSP fiber spun after allowing the spinning solution dissolved in FA to stand for 2 days and the fiber spun immediately after being dissolved in FA for 4 h. The tensile strength of the former fiber was lower than the strength of the latter fiber. This difference can be explained by the difference in the degree of formylation as follows. FA is a known formylating agent, although most researchers who prepared silk fiber by wet spinning with FA have not pointed out about formylation. The formylation of the Ser OH group was confirmed by ¹³C solution nuclear magnetic resonance (NMR), and the time course of formylation of the RSSP film prepared from the FA solution was tracked by Fourier transform infrared spectroscopy. The ¹³C solid-state NMR spectra were also compared between two kinds of the formylated RSSP fibers and indicated that the packing state was tighter for the latter fiber than the former one, which could explain higher tensile strength of the latter fiber in the dry state. The sodium dodecyl sulfate-polyacrylamide gel electrophoresis analysis indicated that the RSSP sample decomposed gradually with storage time in FA and the decomposition has begun partly even at 2 h after dissolution in FA. The decomposition by formylation seems to have no significant effect on the backbone structure of the RSSP fiber, although the packing of the fiber becomes loose as a whole. Finally, preliminary trial of deformylation of the formylated RSSP fiber was performed.

3D Printing of Monolithic Proteinaceous Cantilevers Using Regenerated Silk Fibroin

Silk fibroin, regenerated from Bombyx mori, has shown considerable promise as a printable, aqueous-based ink using a bioinspired salt-bath system in our previous work. Here, we further developed and characterized silk fibroin inks that exhibit concentration-dependent fluorescence spectra at the molecular level. These insights supported extrusion-based 3D printing using concentrated silk fibroin solutions as printing inks. 3D monolithic proteinaceous structures with high aspect ratios were successfully printed using these approaches, including cantilevers only supported at one end. This work provides further insight and broadens the utility of 3D printing with silk fibroin inks for the microfabrication of proteinaceous structures.

From Mesoscopic Functionalization of Silk Fibroin to Smart Fiber Devices for Textile Electronics and Photonics

Bombyx mori silk fibers exhibit significant potential for applications in smart textiles, such as fiber sensors, fiber actuators, optical fibers, and energy harvester. Silk fibroin (SF) from B. mori silkworm fibers can be reconstructed/functionalized at the mesoscopic scale during refolding from the solution state into fibers. This facilitates the mesoscopic functionalization by engaging functional seeds in the refolding of unfolded SF molecules. In particular, SF solutions can be self-assembled into regenerated fiber devices by artificial spinning technologies, such as wet spinning, dry spinning, microfluidic spinning, electrospinning, and direct writing. Meso-functionalization manipulates the SF property from the mesoscopic scale, transforming the original silk fibers into smart fiber devices with smart functionalities, such as sensors, actuators, optical fibers, luminous fibers, and energy harvesters. In this review, the progress of mesoscopic structural construction from SF materials to fiber electronics/photonics is comprehensively summarized, along with the spinning technologies and fiber structure characterization methods. The applications, prospects, and challenges of smart silk fibers in textile devices for wearable personalized healthcare, self-propelled exoskeletons, optical and luminous fibers, and sustainable energy harvesters are also discussed.

Atomistic Simulation of Water Incorporation and Mobility in Bombyx mori Silk Fibroin

Bombyx mori silk fibroin (SF) is a biopolymer that can be processed into materials with attractive properties (e.g., biocompatibility and degradability) for use in a multitude of technical and medical applications (including textiles, sutures, drug delivery devices, tissue scaffolds, etc.). Utilizing the information from experimental and computational SF studies, a simplified SF model has been produced (alanine-glycine [Ala-Gly] _n crystal structure), enabling the application of both molecular dynamic and density functional theory techniques to offer a unique insight into SF-based materials. The secondary structure of the computational model has been evaluated using Ramachandran plots under different environments (e.g., different temperatures and ensembles). In addition, the mean square displacement of water incorporated into the SF model was investigated: the diffusion coefficients, activation energies, most and least favorable positions of water, and trajectory of water diffusion through the SF model are obtained. With further computational study and in combination with experimental data, the behavior/degradation of SF (and similar biomaterials) can be elucidated. Consequently, greater control of the aforementioned technologies may be achieved and positively affect their potential applications.

From Protein Building Blocks to Functional Materials

Proteins are the fundamental building blocks for high-performance materials in nature. Such materials fulfill structural roles, as in the case of silk and collagen, and can generate active structures including the cytoskeleton. Attention is increasingly turning to this versatile class of molecules for the synthesis of next-generation green functional materials for a range of applications. Protein nanofibrils are a fundamental supramolecular unit from which many macroscopic protein materials are formed. In this Review, we focus on the multiscale assembly of such protein nanofibrils formed from naturally occurring proteins into new supramolecular architectures and discuss how they can form the basis of material systems ranging from bulk gels, films, fibers, micro/nanogels, condensates, and active materials. We review current and emerging approaches to process and assemble these building blocks in a manner which is different to their natural evolutionarily selected role but allows the generation of tailored functionality, with a focus on microfluidic approaches. We finally discuss opportunities and challenges for this class of materials, including applications that can be involved in this material system which consists of fully natural, biocompatible, and biodegradable feedstocks yet has the potential to generate materials with performance and versatility rivalling that of the best synthetic polymers.

Spinning Regenerated Silk Fibers with Improved Toughness by Plasticizing with Low Molecular Weight Silk

Low-molecular weight (LMW) silk was utilized as a LMW silk plasticizer for regenerated silk, generating weak physical crosslinks between high-molecular weight (HMW) silk chains in the amorphous regions of a mixed solution of HMW/LMW silk. The plasticization effect of LMW silk was investigated using mechanical testing, Raman spectroscopy, and wide-angle X-ray scattering (WAXS). Small amounts (10%) of LMW silk resulted in a 19.4% enhancement in fiber extensibility and 37.8% increase in toughness. The addition of the LMW silk facilitated the movement of HMW silk chains during drawing, resulting in an increase in molecular chain orientation when compared with silk spun from 100% HMW silk solution. The best regenerated silk fibers produced in this work had an orientation factor of 0.94 and crystallinity of 47.82%, close to the values of natural degummedBombyx mori silk fiber. The approach and mechanism elucidated here can facilitate artificial silk systems with enhanced properties.

Cyclic Expansion/Compression of the Air-Liquid Interface as a Simple Method to Produce Silk Fibers

Self-assembly of recombinant spider silk protein at air-liquid interfaces is used as a starting point to produce homogeneous fiber bundles. The film that is formed on a silk protein solution in a vertically placed syringe is subjected to repeated controlled extension and compression by an oscillating vertical motion. Thereby, a precise breakup of the film can be achieved, followed by transport and roll-up against the syringe wall prior to extraction. Advantages of the method are that it 1) is simple to use; 2) requires a small volume of protein solution (1 mL) at relatively low concentration (1 mg mL^-1 ); 3) can be performed under sterile conditions; 4) does not require any use of coagulants; and 5) is compatible with the addition of viable cells during the process, which thereby are integrated uniformly throughout the fiber.

From Silk Spinning to 3D Printing: Polymer Manufacturing using Directed Hierarchical Molecular Assembly

Silk spinning offers an evolution-based manufacturing strategy for industrial polymer manufacturing, yet remains largely inaccessible as the manufacturing mechanisms in biological and synthetic systems, especially at the molecular level, are fundamentally different. The appealing characteristics of silk spinning include the sustainable sourcing of the protein material, the all-aqueous processing into fibers, and the unique material properties of silks in various formats. Substantial progress has been made to mimic silk spinning in artificial manufacturing processes, despite the gap between natural and artificial systems. This report emphasizes the universal spinning conditions utilized by both spiders and silkworms to generate silk fibers in nature, as a scientific and technical framework for directing molecular assembly into high-performance structures. The preparation of regenerated silk feedstocks and mimicking native spinning conditions in artificial manufacturing are discussed, as is progress and challenges in fiber spinning and 3D printing of silk-composites. Silk spinning is a biomimetic model for advanced and sustainable artificial polymer manufacturing, offering benefits in biomedical applications for tissue scaffolds and implantable devices.

Microfluidic Silk Fibers with Aligned Hierarchical Microstructures

The hierarchical structure of the ECM provides specific niches for tissues to regulate cell behavior, yet the challenge remains to design biomaterial systems for tissue regeneration to recreate such features in vitro. Here, we achieved this goal through the use of aligned hierarchical structures of native silk fibers, generated through the integration of "bottom-up" and "top-down" strategies to generate regenerated silk fibers with aligned nano- to micro-hierarchical structures. To achieve these designs, we assembled and dispersed silk nanofibers (SNF) in formic acid and spun them into fibers using bioinspired microfluidic chips with a geometry mimicking the native silk gland. The fibers generated using this device exhibited aligned hierarchical structure with fiber mechanical properties superior to fibers derived from more traditional spinning approaches with regenerated silk solutions. Besides the improved mechanical properties, Raman spectroscopic results indicated similarly aligned structures to native fibers and active control of cell proliferation, migration, and aggregate orientation. The results indicate the feasibility of developing bioactive silk fiber materials with hierarchical structures to facilitate utility in a range of cell and tissue regeneration scenarios.

Artificial ligament made from silk protein/Laponite hybrid fibers

With developments in tissue engineering, artificial ligaments are expected to be future materials for anterior cruciate ligament (ACL) reconstruction. However, poor healing of the intraosseous part after ACL reconstruction significantly hinders their applications in this field. In this study, a bioactive clay Laponite (LAP) was introduced into the regenerated silk fibroin (RSF) spinning dope to produce functional RSF/LAP hybrid fibers by wet-spinning. These RSF/LAP hybrid fibers were then woven into artificial ligament for ACL reconstruction. The structure and mechanical properties of RSF/LAP hybrid fibers were extensively studied by different means. Results confirmed the presence of LAP in RSF fibers and revealed that the addition of LAP slightly deteriorated the comprehensive mechanical properties of RSF fibers. However, they were still much tougher (with higher breaking energy) than those of degummed natural silkworm silk that was earlier used for making artificial ligament. The artificial ligament woven from RSF/LAP hybrid fibers showed better cytocompatibility and osteogenic differentiation with mouse pre-osteoblasts in vitro than those made from degummed natural silkworm silks and pure RSF fibers. Furthermore, in vivo study in a rat ACL reconstruction model demonstrated that the presence of LAP in the artificial ligament could significantly enhance the graft osseointegration process and also improve the corresponding biomechanical properties of the artificial ligament. Based upon these results, the RSF/LAP hybrid fibers, which can be mass produced by wet-spinning process, are believed to have a great potential for use as artificial ligament materials for ACL reconstruction. STATEMENT OF SIGNIFICANCE: In this study, we successfully introduced Laponite (LAP), a kind of clay that has the function of osteogenic induction, into regenerated silk fibroin (RSF) fibers, which was prepared by a mature wet-spinning method developed in our lab. We believe that through artificial spinning, additional functional components can be added into RSF fibers, which one can hardly achieve with natural silks. We showed that the artificial ligament woven from RSF/LAP hybrid fibers had better cytocompatibility and osteogenic differentiation for mouse pre-osteoblasts in vitro, and significantly enhanced the graft osseointegration process and improved the corresponding biomechanical properties in a rat ACL reconstruction model in vivo, compared to those artificial ligaments made from degummed natural silkworm silks and pure RSF fibers.

Colorless Silk/Copper Sulfide Hybrid Fiber and Fabric with Spontaneous Heating Property under Sunlight

With the increasing demand for comfort, thinness, and warmth of fabrics, various functional fibers have emerged. However, natural silkworm silk, as one of the most widely used natural fibers in textile, faces the issue that it cannot be modified during the spinning process like synthetic fibers. Herein, copper sulfide nanoparticles (CuS NPs) with a near-infrared (NIR) absorption property were first prepared by using regenerated silk fibroin (RSF) as the biological template. Then, trace CuS NPs prepared in RSF solution (no more than 100 ppm) were added into the RSF spinning dope to prepare colorless RSF/CuS hybrid fibers via wet-spinning process. The tensile test of the RSF/CuS hybrid fibers showed that the toughness was improved with the addition of CuS NPs, which completely met the requirements of textile development. The temperature of RSF/CuS hybrid fiber bundles could increase 18.5 °C within 3 min under 1064 nm laser irradiation with power density of 1.0 W/cm². Finally, these RSF/CuS hybrid fiber bundles were woven into silk fabric or embroidered on a cotton fabric. Under the simulated sunlight, the temperature of RSF/CuS fabric could increase to more than 40 °C from room temperature. Also, as per the infrared images, the pattern of embroidery displayed a significant difference in temperature increase as compared to cotton matrix. Based on these results, an almost colorless RSF/CuS hybrid fiber that can be mass produced by wet spinning may have great potential in the fabrication of dyeable, light, and comfortable silk functional fabric with spontaneous heating characteristics under sunlight.

Hierarchically Porous Silk/Activated-Carbon Composite Fibres for Adsorption and Repellence of Volatile Organic Compounds

Fabrics comprised of porous fibres could provide effective passive protection against chemical and biological (CB) threats whilst maintaining high air permeability (breathability). Here, we fabricate hierarchically porous fibres consisting of regenerated silk fibroin (RSF) and activated-carbon (AC) prepared through two fibre spinning techniques in combination with ice-templating-namely cryogenic solution blow spinning (Cryo-SBS) and cryogenic wet-spinning (Cryo-WS). The Cryo-WS RSF fibres had exceptionally small macropores (as low as 0.1 µm) and high specific surface areas (SSAs) of up to 79 m2·g-1. The incorporation of AC could further increase the SSA to 210 m2·g-1 (25 wt.% loading) whilst also increasing adsorption capacity for volatile organic compounds (VOCs).

Engineering Silk Materials: From Natural Spinning to Artificial Processing

Silks spun by the arthropods are "ancient' materials historically utilized for fabricating high-quality textiles. Silks are natural protein-based biomaterials with unique physical and biological properties, including particularly outstanding mechanical properties and biocompatibility. Current goals to produce artificially engineered silks to enable additional applications in biomedical engineering, consumer products, and device fields, have prompted considerable effort towards new silk processing methods using bio-inspired spinning and advanced biopolymer processing. These advances have redefined silk as a promising biomaterial past traditional textile applications and into tissue engineering, drug delivery, and biodegradable medical devices. In this review, we highlight recent progress in understanding natural silk spinning systems, as well as advanced technologies used for processing and engineering silk into a broad range of new functional materials.

Modulating the Mechanical Performance of Macroscale Fibers through Shear-Induced Alignment and Assembly of Protein Nanofibrils

Protein-based fibers are used by nature as high-performance materials in a wide range of applications, including providing structural support, creating thermal insulation, and generating underwater adhesives. Such fibers are commonly generated through a hierarchical self-assembly process, where the molecular building blocks are geometrically confined and aligned along the fiber axis to provide a high level of structural robustness. Here, this approach is mimicked by using a microfluidic spinning method to enable precise control over multiscale order during the assembly process of nanoscale protein nanofibrils into micro- and macroscale fibers. By varying the flow rates on chip, the degree of nanofibril alignment can be tuned, leading to an orientation index comparable to that of native silk. It is found that the Young's modulus of the resulting fibers increases with an increasing level of nanoscale alignment of the building blocks, suggesting that the mechanical properties of macroscopic fibers can be controlled through varying the level of ordering of the nanoscale building blocks. Capitalizing on strategies evolved by nature, the fabrication method allows for the controlled formation of macroscopic fibers and offers the potential to be applied for the generation of further novel bioinspired materials.

Hierarchical Structure of Silk Materials Versus Mechanical Performance and Mesoscopic Engineering Principles

A comprehensive review on the five levels of hierarchical structures of silk materials and the correlation with macroscopic properties/performance of the silk materials, that is, the toughness, strain-stiffening, etc., is presented. It follows that the crystalline binding force turns out to be very important in the stabilization of silk materials, while the β-crystallite networks or nanofibrils and the interactions among helical nanofibrils are two of the most essential structural elements, which to a large extent determine the macroscopic performance of various forms of silk materials. In this context, the characteristic structural factors such as the orientation, size, and density of β-crystallites are very crucial. It is revealed that the formation of these structural elements is mainly controlled by the intermolecular nucleation of β-crystallites. Consequently, the rational design and reconstruction of silk materials can be implemented by controlling the molecular nucleation via applying sheering force and seeding (i.e., with carbon nanotubes). In general, the knowledge of the correlation between hierarchical structures and performance provides an understanding of the structural reasons behind the fascinating behaviors of silk materials.

Laminin-Coated Electrospun Regenerated Silk Fibroin Mats Promote Neural Progenitor Cell Proliferation, Differentiation, and Survival in vitro

Neural progenitor cell (NPC) transplantation is a promising technique for central nervous system (CNS) reconstruction and regeneration. Biomaterial scaffolds, frameworks, and platforms can support NPC proliferation and differentiation in vitro as well as serve as a temporary extracellular matrix after transplantation. However, further applications of biomaterials require improved biological attributes. Silk fibroin (SF), which is produced by Bombyx mori, is a widely used and studied protein polymer for biomaterial application. Here, we prepared aligned and random eletrospun regenerated SF (RSF) scaffolds, and evaluated their impact on the growth of NPCs. First, we isolated NPCs and then cultured them on either laminin-coated RSF mats or conventional laminin-coated coverslips for cell assays. We found that aligned and random RSF led to increases in NPC proliferation of 143.8 ± 13.3% and 156.3 ± 14.7%, respectively, compared to controls. Next, we investigated neuron differentiation and found that the aligned and the random RSF led to increases in increase in neuron differentiation of about 93.2 ± 6.4%, and 3167.1 ± 4.8%, respectively, compared to controls. Furthermore, we measured the survival of NPCs and found that RSF promoted NPC survival, and found there was no difference among those three groups. Finally, signaling pathways in cells cultured on RSF mats were studied for their contributions in neural cell differentiation. Our results indicate that RSF mats provide a functional microenvironment and represent a useful scaffold for the development of new strategies in neural engineering research.

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.

Commercial application of cellulose nano-composites - A review

Cellulose is the biosynthetic product from plants, animals and bacteria. Cellulose is the most abundant polymer having long linear chain like structure composed of (1,4) linked β-D glucopyranosyl units assembled into hierarchical structures of microfibrils with excellent strength and stiffness. And 'nanocellulose' refers to the cellulosic materials with defined nano-scale structural dimensions. They may be cellulose nanocrystal (CNC or NCC), cellulose nanofibers (CNF) or bacterial nanocellulose. Nanocellulose is non-toxic, biodegradable and biocompatible with no adverse effects on health and environment. Due to its low thermal expansion coefficient, high aspect ratio, better tensile strength, good mechanical and optical properties, they find many applications in thermo-reversible and tenable hydrogels, paper making, coating additives, food packaging, flexible screens, optically transparent films and light weight materials for ballistic protection, automobile windows. It also find potential in biopharmaceutical applications such as in drug delivery and for fabricating temporary implants with PHB like sutures, stents etc.

Nanostructured fibers as a versatile photonic platform: radiative cooling and waveguiding through transverse Anderson localization

Broadband high reflectance in nature is often the result of randomly, three-dimensionally structured materials. This study explores unique optical properties associated with one-dimensional nanostructures discovered in silk cocoon fibers of the comet moth, Argema mittrei. The fibers are populated with a high density of air voids randomly distributed across the fiber cross-section but are invariant along the fiber. These filamentary air voids strongly scatter light in the solar spectrum. A single silk fiber measuring ~50 μm thick can reflect 66% of incoming solar radiation, and this, together with the fibers' high emissivity of 0.88 in the mid-infrared range, allows the cocoon to act as an efficient radiative-cooling device. Drawing inspiration from these natural radiative-cooling fibers, biomimetic nanostructured fibers based on both regenerated silk fibroin and polyvinylidene difluoride are fabricated through wet spinning. Optical characterization shows that these fibers exhibit exceptional optical properties for radiative-cooling applications: nanostructured regenerated silk fibers provide a solar reflectivity of 0.73 and a thermal emissivity of 0.90, and nanostructured polyvinylidene difluoride fibers provide a solar reflectivity of 0.93 and a thermal emissivity of 0.91. The filamentary air voids lead to highly directional scattering, giving the fibers a highly reflective sheen, but more interestingly, they enable guided optical modes to propagate along the fibers through transverse Anderson localization. This discovery opens up the possibility of using wild silkmoth fibers as a biocompatible and bioresorbable material for optical signal and image transport.

Protein-Based Fiber Materials in Medicine: A Review

Fibrous materials have garnered much interest in the field of biomedical engineering due to their high surface-area-to-volume ratio, porosity, and tunability. Specifically, in the field of tissue engineering, fiber meshes have been used to create biomimetic nanostructures that allow for cell attachment, migration, and proliferation, to promote tissue regeneration and wound healing, as well as controllable drug delivery. In addition to the properties of conventional, synthetic polymer fibers, fibers made from natural polymers, such as proteins, can exhibit enhanced biocompatibility, bioactivity, and biodegradability. Of these proteins, keratin, collagen, silk, elastin, zein, and soy are some the most common used in fiber fabrication. The specific capabilities of these materials have been shown to vary based on their physical properties, as well as their fabrication method. To date, such fabrication methods include electrospinning, wet/dry jet spinning, dry spinning, centrifugal spinning, solution blowing, self-assembly, phase separation, and drawing. This review serves to provide a basic knowledge of these commonly utilized proteins and methods, as well as the fabricated fibers’ applications in biomedical research.

Using hydrodynamic focusing to predictably alter the diameter of synthetic silk fibers

Spiders and silkworms provide a model of superior processing for multifunctional and highly versatile high-performance fibers. Mimicking the spider's complex control system for chemical and mechanical gradients has remained an ongoing obstacle for synthetic silk production. In this study, the use of hydrodynamic fluid focusing within a 3D printed biomimetic spinning system to recapitulate the biological spinneret is explored and shown to produce predictable, small diameter fibers. Mirroring in silico fluid flow simulations using a hydrodynamic microfluidic spinning technique, we have developed a model correlating spinning rates, solution viscosity and fiber diameter outputs that will significantly advance the field of synthetic silk fiber production. The use of hydrodynamic focusing to produce controlled output fiber diameter simulates the natural silk spinning process and continues to build upon a 3D printed biomimetic spinning platform.

Silk Fibroin Acts as a Self-Emulsifier to Prepare Hierarchically Porous Silk Fibroin Scaffolds through Emulsion-Ice Dual Templates

Silk fibroin (SF) has shown enormous potentials in various fields; however, application of SF in emulsion technology is quite limited. Here, we use SF as a self-emulsifier to form an oil-in-water (O/W) emulsion by emulsifying 1-butanol in SF aqueous solution. This showed that SF possessed strong surface activity to stabilize the O/W emulsion without the need for any other surface-active agent until its solidification because of 1-butanol-induced conformational transition of SF to β-sheet. After freezing the preformed emulsions at -20 °C, robust three-dimensional porous SF scaffolds were prepared without the need for any further post-treatment. The evolution from the O/W emulsion to porous scaffold formation under freezing was tracked, and an emulsion-ice dual template mechanism was proposed for scaffold formation, based on which SF scaffolds with controllable hierarchically porous structures were achieved by tuning the dispersed droplet volume fraction. Furthermore, SF scaffolds with hierarchical porosity showed significantly higher bioactivity toward L929 fibroblasts than that of SF scaffolds with mono macroporosity, highlighting the great asset of this hierarchically porous SF scaffold for broad applications in tissue engineering. Therefore, the strong surface-active characteristic of SF presented here, in addition to its distinct advantages, sheds a bright light on the application of SF in the vast range of emulsion technologies, especially in cosmetic-, food-, and biomedical-related areas.

Bioinspired Fabrication of Polyurethane/Regenerated Silk Fibroin Composite Fibres with Tubuliform Silk-Like Flat Stress⁻Strain Behaviour

Tubuliform silk is one of the seven different types of spider silks, which is well known for its unique tensile behaviour with Flat Tensile Stress⁻Strain (FTSS) curve. It is found that anisotropic microstructure of β-sheets is responsible for this property. In recent years, bioinspired approaches to engineer fibres supported by modern manufacturing systems have been attracting considerable interest. The present paper aims to investigate a strategy to biomimic the FTSS behaviour of tubuliform silk in synthetic polymer composite fibres by blending polyurethane (PU) and regenerated silk fibroin (RSF) at different ratios. Wet spinning of composite fibres results in the reconstruction of β-sheets in the synthetic fibre matrix. PU/RSF composite fibre at a ratio of 75/25 produce a tensile curve with FTSS characteristics. Secondary structural changes in RSF and interchain directions of β-sheets within the fibre are studied using Fourier Transform Infra-red (FTIR) spectroscopy and Transmission Electron Microscopy (TEM), respectively. Interestingly, results of TEM patterns confirm transverse anisotropic properties of RSF β-sheets. The composite fibres also display tuneable mechanical properties with respect to RSF contents.

Integration of stiff graphene and tough silk for the design and fabrication of versatile electronic materials

The production of structural and functional materials with enhanced mechanical properties through the integration of soft and hard components is a common approach to Nature's materials design. However, directly mimicking these optimized design routes in the lab for practical applications remains challenging. For example, graphene and silk are two materials with complementary mechanical properties that feature ultrahigh stiffness and toughness, respectively. Yet no simple and controllable approach has been developed to homogeneously integrate these two components into functional composites, mainly due to the hydrophobicity and chemical inertness of the graphene. In this study, well-dispersed and highly stable graphene/silk fibroin (SF) suspension systems were developed, which are suitable for processing to fabricate polymorphic materials, such as films, fibers, and coatings. The obtained graphene/SF nanocomposites maintain the electronic advantages of graphene, and they also allow tailorable mechanical performance to form including ultrahigh stretchable (with a strain to failure to 611±85%), or high strength (339 MPa) and high stiffness (7.4 GPa) material systems. More remarkably, the electrical resistances of these graphene/SF materials are sensitive to material deformation, body movement, as well as humidity and chemical environmental changes. These unique features promise their utility as wearable sensors, smart textiles, intelligent skins, and human-machine interfaces.

Polymorphic regenerated silk fibers assembled through bioinspired spinning

A variety of artificial spinning methods have been applied to produce regenerated silk fibers; however, how to spin regenerated silk fibers that retain the advantages of natural silks in terms of structural hierarchy and mechanical properties remains challenging. Here, we show a bioinspired approach to spin regenerated silk fibers. First, we develop a nematic silk microfibril solution, highly viscous and stable, by partially dissolving silk fibers into microfibrils. This solution maintains the hierarchical structures in natural silks and serves as spinning dope. It is then spun into regenerated silk fibers by direct extrusion in the air, offering a useful route to generate polymorphic and hierarchical regenerated silk fibers with physical properties beyond natural fiber construction. The materials maintain the structural hierarchy and mechanical properties of natural silks, including a modulus of 11 ± 4 GPa, even higher than natural spider silk. It can further be functionalized with a conductive silk/carbon nanotube coating, responsive to changes in humidity and temperature.

Structural and Mechanical Roles for the C-Terminal Nonrepetitive Domain Become Apparent in Recombinant Spider Aciniform Silk

Spider aciniform (or wrapping) silk is the toughest of the seven types of spider silks/glue due to a combination of high elasticity and strength. Like most spider silk proteins (spidroins), aciniform spidroin (AcSp1) has a large core repetitive domain flanked by relatively short N- and C-terminal nonrepetitive domains (the NTD and CTD, respectively). The major ampullate silk protein (MaSp) CTD has been shown to control protein solubility and fiber formation, but the aciniform CTD function remains unknown. Here, we compare fiber mechanical properties, solution-state structuring, and fibrous state secondary structural composition, and orientation relative to native aciniform silk for two AcSp1 repeat units with or without fused AcSp1- and MaSp-derived CTDs alongside three AcSp1 repeat units without a CTD. The native AcSp1 CTD uniquely modulated fiber mechanical properties, relative to all other constructs, directly correlating to a native-like structural transformation and alignment.

Hierarchical Chitin Fibers with Aligned Nanofibrillar Architectures: A Nonwoven-Mat Separator for Lithium Metal Batteries

Here, we introduce regenerated fibers of chitin (Chiber), the second most abundant biopolymer after cellulose, and propose its utility as a nonwoven fiber separator for lithium metal batteries (LMBs) that exhibits an excellent electrolyte-uptaking capability and Li-dendrite-mitigating performance. Chiber is produced by a centrifugal jet-spinning technique, which allows a simple and fast production of Chibers consisting of hierarchically aligned self-assembled chitin nanofibers. Following the scrutinization on the Chiber-Li-ion interaction via computational methods, we demonstrate the potential of Chiber as a nonwoven mat-type separator by monitoring it in Li-O₂ and Na-O₂ cells.