Technological advances in electrospinning of nanofibers

Antibiotic delivery in the presence of green AgNPs using multifunctional bilayer carrageenan nanofiber/sodium alginate nanohydrogel for rapid control of wound infections

This study constructed bilayer nano-hydrogels using solvent casting and electrospinning techniques. The first layer consisted of a hydrogel containing sodium alginate and gellan gum, while the second layer was a carrageenan/polyvinyl alcohol nanofibrous membrane. The nanohydrogels were prepared with different doses of doxycycline antibiotic (0.12, 0.06, 0.03 g) and a fixed amount of silver nanoparticles (0.012 g), which were synthesized using the green method including Capparis spinosa leaf extract. The films were tested for their mechanical properties, swelling behavior, XRD, and FTIR, and their morphology was characterized using SEM. The biological properties of the nanohydrogels were also extensively assayed. X-ray diffraction analysis showed peak 111 for silver nanoparticles. Incorporating silver nanoparticles significantly enhanced nanohydrogels' mechanical and antibacterial properties and improved their ability to heal wounds. Nanohydrogels exhibited biodegradability, biocompatibility, anti-inflammatory properties (57.63 %), and high cell viability (>85 %) in laboratory conditions. The study confirmed that wound dressings containing doxycycline with controlled release are highly effective against pathogenic bacteria and prevent the formation of biofilms (92 %). The rats in-vivo study demonstrated that 100 % wound closure was achieved in nanohydrogels containing SA/GG/PVA/CAR/AgNPs/DOX0.12 after 14 days. The films could potentially lead to the development of new treatments against bacterial infections and inflammatory conditions of wounds.

Optimization of Electrospun Bilayer Vascular Grafts through Assessment of the Mechanical Properties of Monolayers

Small-diameter vascular grafts must be obtained with the most appropriate materials and design selection to harmoniously display a variety of features, including adequate tensile strength, compliance, burst strength, biocompatibility, and biodegradability against challenging physiological and hemodynamic conditions. In this study, monolayer vascular grafts with randomly distributed or radially oriented fibers are produced using neat, blended, and copolymer forms of polycaprolactone (PCL) and poly(lactic acid) (PLA) via the electrospinning technique. The blending ratio is varied by increasing 10 in the range of 50-100%. Bilayer graft designs are realized by determining the layers with a random fiber distribution for the inner layer and radial fiber orientation for the outer layer. SEM analysis, wall thickness and fiber diameter measurements, tensile strength, elongation, burst strength, and compliance tests are done for both mono- and bilayer scaffolds. The findings revealed that the scaffolds made of neat PCL show more flexibility than the neat PLA samples, which possess higher tensile strength values than neat PCL scaffolds. Also, in blended samples, the tensile strength values do not show a significant improvement, whereas the elongation values are enhanced in tubular samples, depending on the blending ratio. Also, neat poly(l-lactide-co-caprolactone) (PLCL) samples have both higher elongation and strength values than neat and blended scaffolds, with some exceptions. The blended specimens comprising a combination of PCL and PLA, with blending ratios of 80/20 and 70/30, exhibited the most elevated burst pressures. Conversely, the PLCL scaffolds demonstrated superior compliance levels. These findings suggest that the blending approach and fiber orientation offer enhanced burst strength, while copolymer utilization in PLCL scaffolds without fiber alignment enhances their compliance properties. Thus, it is evident that using a copolymer instead of blending PCL and PLA and combining the PLCL layer with PCL and PLA monolayers in bilayer vascular graft design is promising in terms of mechanical and biological properties.

Innovative Electrospun Nanofiber Mats Based on Polylactic Acid Composited with Silver Nanoparticles for Medical Applications

Nanofibers are some of the most attractive materials that can modify functionalities for developing new kinds of specific applications and are mainly used as a biomedical material. Herein, we designed and prepared antibacterial nonwoven fiber mats of PLA and PLA composited with Ag nanoparticles by electrospinning. The effects of varying filler contents on their chemical, surface morphology, thermal, water absorbency, and antibacterial properties were investigated using FTIR, SEM/EDS, DSC, swelling ratio, and qualitative and quantitative antibacterial tests. FTIR and EDS spectra indicated that Ag nanoparticles were incorporated in the PLA without chemical bonding. SEM revealed that the average diameter of the PLA nanofibers containing the Ag nanoparticles was more significant than those without those particles. In addition, fiber diameters are proportional to the amount of Ag nanoparticle contents. DSC indicated that the Ag nanoparticles can be incorporated within the PLA matrix without strongly affecting their thermal properties. Moreover, the crystallinity of the composite nonwoven fiber mats was higher than those of fiber mats in the neat PLA. However, TGA revealed that the loaded Ag can improve the thermal stability of the PLA electrospun fiber mats. Accordingly, the antibacterial activities revealed that all the composite nanofiber mats exhibited excellent resistance against S. aureus and E. coli bacterial strains. In addition, in the cell toxicity study, all produced hybrids of nonwoven fiber mats induced a reduction in cell viability for the L929 fibroblast cells. Our results suggest that the designed and prepared nonwoven fiber mats may have good potential for use in the biomedical field, particularly in wound dressing applications.

The effect of κ-carrageenan and ursolic acid on the physicochemical properties of the electrospun nanofibrous mat for biomedical application

Wound dressing materials such as nanofiber (NF) mats have gained a lot of attention in recent years owing to their wonderful effect on accelerating the healing process and protection of wounds. In this regard, three different types of NF mats were fabricated using pure polyvinylpyrrolidone (PVP), PVP/κ-carrageenan (KG), and ursolic acid (UA) in the optimal PVP/KG ratio by electrospinning method to apply them as wound dressings. The morphology, chemical structure, degradation, porosity, mechanical properties and antioxidant activity of the produced NFs were investigated. Moreover, cell studies (e.g., cell proliferation, adhesion, and migration) and their antibacterial properties were evaluated. Adding KG and UA reduced the mean diameter size of the PVP-based NFs to ∼98 nm in the optimal sample, with defect-free morphology. The PVP/KG/UA 0.25 % exhibited the highest porosity, hydrophilicity, and degradation rate and a wound closure rate of 60 %, 2.5 times higher than that of the control group. Furthermore, this sample's proliferation and antibacterial ability were significantly higher than the other groups. These findings confirmed that the produced UA-loaded NFs have excellent properties as wound dressing.

Electrospun Poly(carbonate-urea-urethane)s Nonwovens with Shape-Memory Properties as a Potential Biomaterial

Poly(carbonate-urea-urethane) (PCUU)-based scaffolds exhibit various desirable properties for tissue engineering applications. This study thus aimed to investigate the suitability of PCUU as polymers for the manufacturing of nonwoven mats by electrospinning, able to closely mimic the fibrous structure of the extracellular matrix. PCUU nonwovens of fiber diameters ranging from 0.28 ± 0.07 to 0.82 ± 0.12 μm were obtained with an average surface porosity of around 50-60%. Depending on the collector type and solution concentration, a broad range of tensile strengths (in the range of 0.3-9.6 MPa), elongation at break (90-290%), and Young's modulus (5.7-26.7 MPa) at room temperature of the nonwovens could be obtained. Furthermore, samples collected on the plate collector showed a shape-memory effect with a shape-recovery ratio (Rr) of around 99% and a shape-fixity ratio (Rf) of around 96%. Biological evaluation validated the inertness, stability, and lack of cytotoxicity of PCUU nonwovens obtained on the plate collector. The ability of mesenchymal stem cells (MSCs) and endothelial cells (HUVECs) to attach, elongate, and grow on the surface of the nonwovens suggests that the manufactured nonwovens are suitable scaffolds for tissue engineering applications.

The Manufacturing Conditions for the Direct and Reproducible Formation of Electrospun PCL/Gelatine 3D Structures for Tissue Regeneration

Electrospinning is a versatile technique for fabricating nanofibrous scaffolds for tissue engineering applications. However, the direct formation of 3D sponges through electrospinning has previously not been reproducible. We used a Taguchi experimental design approach to optimise the electrospinning parameters for forming PCL and PCL/gelatine 3D sponges. The following parameters were investigated to improve sponge formation: solution concentration, humidity, and solution conductivity. Pure PCL sponges were achievable. However, a much fluffier sponge formed by increasing the solution conductivity with gelatine. The optimal conditions for sponge formation 24 w/v% 80:20 PCL:gelatine on aluminium foil at ≥70% humidity, 15 cm, 22 kV and 1500 µL/h. The resulting sponge had a highly porous structure with a fibre diameter of ~1 µm. They also supported significantly higher cell viability than 2D electrospun mats, dropcast films of the same material and even the TCP positive control. Our study demonstrates that the direct formation of PCL/gelatine 3D sponges through electrospinning is feasible and promising for tissue engineering applications. The sponges have a highly porous structure and support cell viability, which are essential properties for tissue engineering scaffolds. Further studies are needed to optimise the manufacturing process and evaluate the sponges' long-term performance in vivo.

Electrospun Nanofibers for Biomedical, Sensing, and Energy Harvesting Functions

The process of electrospinning is over a century old, yet novel material and method achievements, and later the addition of nanomaterials in polymeric solutions, have spurred a significant increase in research innovations with several unique applications. Significant improvements have been achieved in the development of electrospun nanofibrous matrices, which include tailoring compositions of polymers with active agents, surface functionalization with nanoparticles, and encapsulation of functional materials within the nanofibers. Recently, sequentially combining fabrication of nanofibers with 3D printing was reported by our group and the synergistic process offers fiber membrane functionalities having the mechanical strength offered by 3D printed scaffolds. Recent developments in electrospun nanofibers are enumerated here with special emphasis on biomedical technologies, chemical and biological sensing, and energy harvesting aspects in the context of e-textile and tactile sensing. Energy harvesting offers significant advantages in many applications, such as biomedical technologies and critical infrastructure protection by using the concept of finite state machines and edge computing. Many other uses of devices using electrospun nanofibers, either as standalone or conjoined with 3D printed materials, are envisaged. The focus of this review is to highlight selected novel applications in biomedical technologies, chem.-bio sensing, and broadly in energy harvesting for use in internet of things (IoT) devices. The article concludes with a brief projection of the future direction of electrospun nanofibers, limitations, and how synergetic combination of the two processes will open pathways for future discoveries.

Advances in Biomedical Applications of Solution Blow Spinning

In recent years, Solution Blow Spinning (SBS) has emerged as a new technology for the production of polymeric, nanocomposite, and ceramic materials in the form of nano and microfibers, with similar features to those achieved by other procedures. The advantages of SBS over other spinning methods are the fast generation of fibers and the simplicity of the experimental setup that opens up the possibility of their on-site production. While producing a large number of nanofibers in a short time is a crucial factor in large-scale manufacturing, in situ generation, for example, in the form of sprayable, multifunctional dressings, capable of releasing embedded active agents on wounded tissue, or their use in operating rooms to prevent hemostasis during surgical interventions, open a wide range of possibilities. The interest in this spinning technology is evident from the growing number of patents issued and articles published over the last few years. Our focus in this review is on the biomedicine-oriented applications of SBS for the production of nanofibers based on the collection of the most relevant scientific papers published to date. Drug delivery, 3D culturing, regenerative medicine, and fabrication of biosensors are some of the areas in which SBS has been explored, most frequently at the proof-of-concept level. The promising results obtained demonstrate the potential of this technology in the biomedical and pharmaceutical fields.

A Review of Chitosan and Chitosan Nanofiber: Preparation, Characterization, and Its Potential Applications

Chitosan is produced by deacetylating the abundant natural chitin polymer. It has been employed in a variety of applications due to its unique solubility as well as its chemical and biological properties. In addition to being biodegradable and biocompatible, it also possesses a lot of reactive amino side groups that allow for chemical modification and the creation of a wide range of useful derivatives. The physical and chemical characteristics of chitosan, as well as how it is used in the food, environmental, and medical industries, have all been covered in a number of academic publications. Chitosan offers a wide range of possibilities in environmentally friendly textile processes because of its superior absorption and biological characteristics. Chitosan has the ability to give textile fibers and fabrics antibacterial, antiviral, anti-odor, and other biological functions. One of the most well-known and frequently used methods to create nanofibers is electrospinning. This technique is adaptable and effective for creating continuous nanofibers. In the field of biomaterials, new materials include nanofibers made of chitosan. Numerous medications, including antibiotics, chemotherapeutic agents, proteins, and analgesics for inflammatory pain, have been successfully loaded onto electro-spun nanofibers, according to recent investigations. Chitosan nanofibers have several exceptional qualities that make them ideal for use in important pharmaceutical applications, such as tissue engineering, drug delivery systems, wound dressing, and enzyme immobilization. The preparation of chitosan nanofibers, followed by a discussion of the biocompatibility and degradation of chitosan nanofibers, followed by a description of how to load the drug into the nanofibers, are the first issues highlighted by this review of chitosan nanofibers in drug delivery applications. The main uses of chitosan nanofibers in drug delivery systems will be discussed last.

Advances in Electrospun Materials and Methods for Li-Ion Batteries

Electronic devices commonly use rechargeable Li-ion batteries due to their potency, manufacturing effectiveness, and affordability. Electrospinning technology offers nanofibers with improved mechanical strength, quick ion transport, and ease of production, which makes it an attractive alternative to traditional methods. This review covers recent morphology-varied nanofibers and examines emerging nanofiber manufacturing methods and materials for battery tech advancement. The electrospinning technique can be used to generate nanofibers for battery separators, the electrodes with the advent of flame-resistant core-shell nanofibers. This review also identifies potential applications for recycled waste and biomass materials to increase the sustainability of the electrospinning process. Overall, this review provides insights into current developments in electrospinning for batteries and highlights the commercialization potential of the field.

Microscale and Macroscale Deformation Behavior of Electrospun Polymeric Nanofiber Membranes Using In Situ SEM during Mechanical Testing

Electrospun nanofiber membranes show high potential in various application fields (e.g., filtration, catalysis, and sensing). Nevertheless, knowledge of the mechanical behavior, and more specifically, the deformation of nanofiber membranes is still limited today which can complicate the appliance of nanofiber membranes in applications where they are mechanically loaded. In this paper, we, therefore, analyzed the mechanical behavior of polymeric nanofiber membranes with different fiber orientations (random and aligned) extensively. Polyamide 6 was used as a representative reference polymer for proof-of-concept. Mechanical tests show that all membranes have a coherent deformation behavior at the macroscale up to the point of fracture. Large variations in stiffness, ultimate strength, and ultimate strain were observed between membranes with different fiber orientations (Random: E-mod: 370 ± 34 MP; UTS: 38.5 ± 6.0 MPa; εmax: 30.0 ± 2.8%; Parallel aligned: E-mod: 753 ± 11 MPa; UTS: 55.4 ± 0.8 MPa; εmax: 12.0 ± 0.1%; Perpendicular aligned: E-mod: 24.1 ± 3.7 MPa; UTS:/; εmax: >40%). This shows the versatility and tunability of the mechanical behavior of these nanofiber membranes. At the microscale, the fibrous structure results in deformation mechanisms that resist failure formation and progression when the membrane is mechanically loaded. This results in a high fracture resistance, even for pre-damaged membranes. Realignment of the fibers along the loading direction causes crack tip blunting, locally reinforcing the membrane.

Biodegradable Polymer Electrospinning for Tendon Repairment

With the degradation after aging and the destruction of high-intensity exercise, the frequency of tendon injury is also increasing, which will lead to serious pain and disability. Due to the structural specificity of the tendon tissue, the traditional treatment of tendon injury repair has certain limitations. Biodegradable polymer electrospinning technology with good biocompatibility and degradability can effectively repair tendons, and its mechanical properties can be achieved by adjusting the fiber diameter and fiber spacing. Here, this review first briefly introduces the structure and function of the tendon and the repair process after injury. Then, different kinds of biodegradable natural polymers for tendon repair are summarized. Then, the advantages and disadvantages of three-dimensional (3D) electrospun products in tendon repair and regeneration are summarized, as well as the optimization of electrospun fiber scaffolds with different bioactive materials and the latest application in tendon regeneration engineering. Bioactive molecules can optimize the structure of these products and improve their repair performance. Importantly, we discuss the application of the 3D electrospinning scaffold's superior structure in different stages of tendon repair. Meanwhile, the combination of other advanced technologies has greater potential in tendon repair. Finally, the relevant patents of biodegradable electrospun scaffolds for repairing damaged tendons, as well as their clinical applications, problems in current development, and future directions are summarized. In general, the use of biodegradable electrospun fibers for tendon repair is a promising and exciting research field, but further research is needed to fully understand its potential and optimize its application in tissue engineering.

Enhanced electrocatalytic performance for oxygen evolution reaction via active interfaces of Co3O4arrays@FeOx/Carbon cloth heterostructure by plasma-enhanced atomic layer deposition

Oxygen evolution reaction (OER) is a necessary procedure in various devices including water splitting and rechargeable metal-air batteries but required a higher potential to improve oxygen evolution efficiency due to its slow reaction kinetics. In order to solve this problem, a heterostructured electrocatalyst (Co₃O₄@FeO_x/CC) is synthesized by deposition of iron oxides (FeO_x) on carbon cloth (CC) via plasma-enhanced atomic layer deposition, then growth of the cobalt oxide (Co₃O₄) nanosheet arrays. The deposition cycle of FeO_xon the CC strongly influences thein situgrowth and distribution of Co₃O₄nanosheets and electronic conductivity of the electrocatalyst. Owing to the high accessible and electroactive areas and improved electrical conductivity, the free-standing electrode of Co₃O₄@FeO_x/CC with 100 deposition cycles of FeO_xexhibits excellent electrocatalytic performance for OER with a low overpotential of 314.0 mV at 10 mA cm^-2and a small Tafel slope of 29.2 mV dec^-1in alkaline solution, which is much better than that of Co₃O₄/CC (448 mV), and even commercial RuO₂(380 mV). This design and optimization strategy shows a promising way to synthesize ideally designed catalytic architectures for application in energy storage and conversion.

Boron nitride decorated poly(vinyl alcohol)/poly(acrylic acid) composite nanofibers: A promising material for biomedical applications

In this study, polyvinyl alcohol (PVA) and polyacrylic acid (PAA) nanofibers loaded with boron nitride nanoparticles (mBN) were fabricated by using electrospinning and crosslinked by heat treatment. The physical, chemical, and mechanical properties, hydrophilic behavior, and degradability of composite nanofibers were evaluated. The mechanical properties such as elastic modulus, elongation percentage at the break, and mechanical strength of PVA/PAA nanofibers improved with mBN loading. The thermal conductivity of composite nanofibers reached 0.12 W/m·K at mBN content of 1.0 wt% due to the continuous heat conduction pathways of mBN. In the meantime, while there was no cytotoxicity recorded for both L929 and HUVEC cell lines for all composite nanofibers, the antimicrobial efficiency improved with the incorporation of mBN compared with PVA/PAA and recorded as 68.8% and 75.1% for Escherichia coli and Staphylococcus aureus, respectively. On this basis, the present work proposes a promising biomaterial for biomedical applications such as dual drug delivery, particularly including both hydrophobic and hydrophilic drugs or wound dressing.

Optimal delivery of poorly soluble drugs using electrospun nanofiber technology: Challenges, state of the art, and future directions

Poor aqueous solubility of both, existing drug molecules and those which are currently in the developmental stage, have posed a great challenge to pharmaceutical scientists because they often exhibit poor dissolution behavior and subsequent poor and erratic bioavailability. This has triggered extensive research to explore nanotechnology-based technology platforms for possible rescue. Recently, nanofibers have been exploited widely for diverse biomedical applications including for drug delivery. Electrospun nanofibers are capable of preserving the homogeneously loaded therapeutic agents in amorphous state potentialy impairing devitrification. The present review aims at providing an overview of the various key factors that affect the electrospinning process and characteristics of the nanofibers while fabrication of drug loaded nanofibers for poorly soluble drug candidates. The review explores various methodological advancements in the electrospinning process and set-ups for production scale-up. The various types of electrospun nanofibers (like simple matrix, core-sheath, Janus, and inclusion complex nanofibers) that have been exploited for the delivery of poorly soluble drugs are also critically assessed. This article is categorized under: Therapeutic Approaches and Drug Discovery > Emerging Technologies.

Acoustic characterization of nanofibers for optimization with porous substrate

Nanofiber-porous systems comprising a porous substrate overlaid with nanofiber weave offer the potential for higher acoustic absorption than the substrate alone with negligible increase in thickness. The characterization of nanofibers from acoustic measurements is investigated in this work, and a regression model for predicting their acoustic properties from a single physical parameter is proposed to enable the design of nanofiber-porous systems directly from fabrication parameters. Characterization as a resistive screen via Johnson-Champoux-Allard and lumped element models for transfer matrix computations of absorption coefficient for nanofiber-porous systems exhibited good agreement with the measured spectra. The lumped element model was chosen as it was defined by fewer parameters and did not require nanofiber layer thickness measurements, eliminating the associated uncertainty. A regression model for lumped element parameters vs areal density established a design tool based on a single, easily measured physical property for optimized absorption at target frequencies without prior acoustic characterization of the nanofiber layer, enabling the analysis of complex acoustic networks incorporating nanofiber-porous systems. Practical considerations of applying adhesives at the nanofiber-porous interface were studied to evaluate possible enhancement of acoustic performance. For comparison with prior work by others, flow resistances from physical measurement and acoustic characterization were compared.

Electrospun nanofibers for 3-D cancer models, diagnostics, and therapy

As one of the leading causes of global mortality, cancer has prompted extensive research and development to advance efficacious drug discovery, sustained drug delivery and improved sensitivity in diagnosis. Towards these applications, nanofibers synthesized by electrospinning have exhibited great clinical potential as a biomimetic tumor microenvironment model for drug screening, a controllable platform for localized, prolonged drug release for cancer therapy, and a highly sensitive cancer diagnostic tool for capture and isolation of circulating tumor cells in the bloodstream and for detection of cancer-associated biomarkers. This review provides an overview of applied nanofiber design with focus on versatile electrospinning fabrication techniques. The influence of topographical, physical, and biochemical properties on the function of nanofiber assemblies is discussed, as well as current and foreseeable barriers to the clinical translation of applied nanofibers in the field of oncology.

Fluoropolymers and Their Nanohybrids As Energy Materials: Application to Fuel Cells and Energy Harvesting

The current review article provides deep insight into the fluoropolymers and their applications in energy technology, especially in the field of energy harvesting and the development of fuel cell electrolyte polymeric membranes. Fluoropolymers have gained wide attention in the field of energy applications due to their versatile properties. The incorporation of nanofillers within the fluoropolymer to develop the nanohybrid results in an enhancement in the properties, like thermal, mechanical, gas permeation, different fuel cross-over phenomena through the membrane, hydrophilic/hydrophobic nature, ion transport, and piezo-electric properties for fabricating energy devices. The properties of nanohybrid materials/membranes are influenced by several factors, such as type of filler, their size, amount of filler, level of dispersion, surface acidity, shape, and formation of networking within the polymer matrix. Fluoropolymer-based nanohybrids have replaced several commercial materials due to their chemical inertness, better efficacy, and durability. The addition of certain electroactive fillers in the polymer matrix enhances the polar phase, which enhances the applicability of the hybrid for fuel cell and energy-harvesting applications. Poly(vinylidene fluoride) is one of the remarkable fluoropolymers in the field of energy applications such as fuel cell and piezoelectric energy harvesting. In the present review, a detailed discussion of the different kinds of nanofillers and their role in energy harvesting and fuel cell electrolyte membranes is projected.

Culture and maintenance of neural progressive cells on cellulose acetate/graphene‑gold nanocomposites

In this study, the first CA nanofibers were fabricated by electrospinning under optimal conditions: flow rate of 0.5 ml/h, a voltage of 20 kV, electrospinning distance of 15 cm, and an internal temperature of 25 °C, and humidity of 38%. The used Graphene/gold nanoparticles for CA performance improvement were examined by TGA, XRD, and SEM analysis. Then the CA/graphene‑gold nanocomposite was synthesized under optimum electrospinning conditions: flow rate 3 ml/h, voltage 20 kV, electrospinning distance 15 cm, internal temperature 26 °C, and humidity 36%. The SEM images revealed that the nanofibers' thicknesses of Graphene‑gold NPs (CA₁) and Chitosan (CA₂) were 350 and 120 nm, respectively. The XRD diagrams of CA₀, CA₁ and CA₂ revealed the peaks at 2θ, 8°, and 21° with Miller indices of (001) and (110) are related to CA (CA₀), which proves its presence in other scaffolds. The FTIR analysis of samples indicated the presence of graphene‑gold NPs in scaffolding CA₁ and CA₂. The CA₂ nanofibers exhibited a high-water absorption capacity of about 2500% with the water contact-angle and Swelling method. The antibacterial properties of this nanocomposite were also confirmed by an antibacterial test on Staphylococcus aureus bacteria. The growth of Schwann cells on three scaffolds showed the highest growth of cells on CA₁ scaffolds.

Near-Field Electrospinning: Crucial Parameters, Challenges, and Applications

Near-field electrospinning (NFES) is a micro- or nanofiber production technology based on jetting molten polymer or polymer solution. Thanks to the programmable collector and nozzle movement, it can generate designed patterns in the presence of an electric field. Despite a few shortcomings of NFES, its high resolution, simplicity, precision, high throughput, reproducibility, and low costs have convinced researchers to employ it for various purposes. Furthermore, as the paradigm of fiber-based structures shifts from random textures toward delicate designs, NFES can bridge the gap between existing inefficient processes and aspired technologies for precise patterning. NFES facilitates the production of ultrafine nanofibers because it can be used to fabricate them in every laboratory. These robust fibers are convenient tools for small and additive manufacturing. As such, NFES is considered a potent additive fabrication technology that facilitates the production of complicated patterns as well. It is suggested that near-field electrospun fibers exhibit outstanding results in various applications, owing to their precise and controllable positioning. Meanwhile, the ongoing development of NFES has yet to reach its climax, making it attractive for further research. In this review, the basic principles of NFES, derivatives, limitations, and applications in nanomanufacturing, tissue engineering, microscale electronics, biosensors, and optics are presented.

Recent update on electrospinning and electrospun nanofibers: current trends and their applications

Electrospinning is a versatile and viable technique for generating ultrathin fibers. Remarkable progress has been made in techniques for creating electro-spun and non-electro-spun nanofibers. Nanofibers were the center of attention for industries and researchers due to their simplicity in manufacture and setup. The review discusses a thorough overview of both electrospinning and non-electrospinning processes, including their setup, fabrication process, components, and applications. The review starts with an overview of the field of nanotechnology, the background of electrospinning, the surge in demand for nanofiber production, the materials needed to make nanofibers, and the critical process variables that determine the characteristics of nanofibers. Additionally, the diverse applications of electrospun nanofibers, such as smart mats, catalytic supports, filtration membranes, energy storage/heritage components, electrical devices (batteries), and biomedical scaffolds, are then covered. Further, the review concentrates on the most recent and pertinent developments in nanofibers that are connected to the use of nanofibers, focusing on the most illustrative cases. Finally, challenges and their possible solutions, marketing, and the future prospects of nanofiber development are discussed.

Electrospinning is a versatile and viable technique for generating ultrathin fibers.

Porous Carbon Nanofibers with Heteroatoms Doped by Electrospinning Exhibit Excellent Acetone and Carbon Dioxide Adsorption Performance: The Contributions of Pore Structure and Functional Groups

Rich chemical properties and a well-developed pore structure are the key factors of porous materials for gas storage. Herein, rich heteroatom-doped porous carbon nanofibers (U₁K₂-X) with a large surface area were prepared by electrospinning followed by potassium hydroxide (KOH) activation. Low-cost urea was chosen as the nitrogen source and structural guiding agent. U₁K₂-X have a high specific surface area (628-2688 m² g^-1), excellent pore volume (0.468-1.571 cm³ g^-1), and abundant nitrogen (2.5-12.8 atom %) and oxygen (4.5-12.5 atom %) contents. Acetone and carbon dioxide were used as target adsorbents to evaluate the adsorption properties of U₁K₂-X by experiments. These U₁K₂-X exhibit excellent adsorption performance (260.03-955.74 mg g^-1, 25 °C, 18 kPa) and multilayer adsorption (the adsorption layer number n > 2) for acetone, which is mainly attributed to the large specific surface area and pore volume. Besides this, the carbon dioxide uptake reached 2.73-3.34 mmol g^-1 at 25 °C. This was attributed to the combination of high nitrogen-oxygen contents and microporous structure. Furthermore, U₁K₂-X show the desirable repeatability. This study provides a new direction for the preparation of heteroatom-doped porous carbon nanofibers, which will be a promising material for gas adsorption.

Effects of Viscosities and Solution Composition on Core-Sheath Electrospun Polycaprolactone(PCL) Nanoporous Microtubes

Vascularization for tissue engineering applications has been challenging over the past decades. Numerous efforts have been made to fabricate artificial arteries and veins, while few focused on capillary vascularization. In this paper, core-sheath electrospinning was adopted to fabricate nanoporous microtubes that mimic the native capillaries. The results showed that both solution viscosity and polyethylene oxide (PEO) ratio in polycaprolactone (PCL) sheath solution had significant effects on microtube diameter. Adding PEO into PCL sheath solution is also beneficial to surface pore formation, although the effects of further increasing PEO showed mixed results in different viscosity groups. Our study showed that the high viscosity group with a PCL/PEO ratio of 3:1 resulted in the highest average microtube diameter (2.14 µm) and pore size (250 nm), which mimics the native human capillary size of 1–10 µm. Therefore, our microtubes show high potential in tissue vascularization of engineered scaffolds.

Circulatory Management of Polymer Waste: Recycling into Fine Fibers and Their Applications

In modern society, it is impossible to imagine life without polymeric materials. However, managing the waste composed of these materials is one of the most significant environmental issues confronting us in the present day. Recycling polymeric waste is the most important action currently available to reduce environmental impacts worldwide and is one of the most dynamic areas in industry today. Utilizing this waste could not only benefit the environment but also promote sustainable development and circular economy management. In its program statement, the European Union has committed to support the use of sorted polymeric waste. This study reviews recent attempts to recycle this waste and convert it by alternative technologies into fine, nano-, and microscale fibers using electrospinning, blowing, melt, or centrifugal spinning. This review provides information regarding applying reprocessed fine fibers in various areas and a concrete approach to mitigate the threat of pollution caused by polymeric materials.

Development and Applications of MXene-Based Functional Fibers

The increasing interest toward wearable and portable electronic devices calls for multifunctional materials and fibers/yarns capable of seamless integration with everyday textiles. To date, one particular gap inhibiting the development of such devices is the production of robust functional fibers with improved electronic conductivity and electrochemical energy storage capability. Recent efforts have been made to produce functional fibers with 2D carbides known as MXenes to address these demands. Ti₃C₂T_x MXene, in particular, is known for its metallic conductivity and high volumetric capacitance, and has shown promise for fibers and textile-based devices when used either as an additive, coating or the main fiber component. In this spotlight article, we highlight the recent exciting developments in our diverse efforts to fabricate MXene functionalized fibers, along with a critical evaluation of the challenges in processing, which directly affect macroscale material properties and the performance of the subsequent prototype devices. We also provide our assessment of observed and foreseen challenges of the current manufacturing methods and the opportunities arising from recent advances in the development of MXene fibers and paving future avenues for textile design and practical use in advanced applications.

Recent applications of electrical, centrifugal, and pressurised emerging technologies for fibrous structure engineering in drug delivery, regenerative medicine and theranostics

Advancements in technology and material development in recent years has led to significant breakthroughs in the remit of fiber engineering. Conventional methods such as wet spinning, melt spinning, phase separation and template synthesis have been reported to develop fibrous structures for an array of applications. However, these methods have limitations with respect to processing conditions (e.g. high processing temperatures, shear stresses) and production (e.g. non-continuous fibers). The materials that can be processed using these methods are also limited, deterring their use in practical applications. Producing fibrous structures on a nanometer scale, in sync with the advancements in nanotechnology is another challenge met by these conventional methods. In this review we aim to present a brief overview of conventional methods of fiber fabrication and focus on the emerging fiber engineering techniques namely electrospinning, centrifugal spinning and pressurised gyration. This review will discuss the fundamental principles and factors governing each fabrication method and converge on the applications of the resulting spun fibers; specifically, in the drug delivery remit and in regenerative medicine.

Needleless electrospun phytochemicals encapsulated nanofibre based 3-ply biodegradable mask for combating COVID-19 pandemic

The emergence of COVID-19 pandemic has severely affected human health and world economies. According to WHO guidelines, continuous use of face mask is mandatory for personal protection for restricting the spread of bacteria and virus. Here, we report a 3-ply cotton-PLA-cotton layered biodegradable face-mask containing encapsulated phytochemicals in the inner-filtration layer. The nano-fibrous PLA filtration layer was fabricated using needleless electrospinning of PLA & phytochemical-based herbal-extracts. This 3-layred face mask exhibits enhanced air permeability with a differential pressure of 35.78 Pa/cm² and superior bacterial filtration efficiency of 97.9% compared to conventional face masks. Close-packed mesh structure of the nano-fibrous mat results in effective adsorption of particulate matter, aerosol particles, and bacterial targets deep inside the filtration layer. The outer hydrophobic layer of mask exhibited effective blood splash resistance up to a distance of 30 cm, ensuring its utilization for medical practices. Computational analysis of constituent phytochemicals using the LibDock algorithm predicted inhibitory activity of chemicals against the protein structured bacterial sites. The computational analysis projected superior performance of phytochemicals considering the presence of stearic acid, oleic acid, linoleic acid, and Arachidic acid exhibiting structural complementarity to inhibit targeted bacterial interface. Natural cotton fibers and PLA bio-polymer demonstrated promising biodegradable characteristics in the presence of in-house cow-dung based biodegradation slurry. Addition of jaggery to the slurry elevated the biodegradation performance, resulting in increment of change of weight from 07% to 12%. The improved performance was attributed to the increased sucrose content in biodegradation slurry, elevating the bacterial growth in the slurry. An innovative face mask has shown promising results for utilization in day-to-day life and medical frontline workers, considering the post-pandemic environmental impacts.

Review on Electrospun Nanofiber-Applied Products

Electrospinning technology, which was previously known as a scientific interdisciplinary research approach, is now ready to move towards a practice-based interdisciplinary approach in a variety of fields, progressively. Electrospun nanofiber-applied products are made directly from a nonwoven fabric-based membranes prepared from polymeric liquids involving the application of sufficiently high voltages during electrospinning. Today, electrospun nanofiber-based materials are of remarkable interest across multiple fields of applications, such as in electronics, sensors, functional garments, sound proofing, filters, wound dressing and scaffolds. This article presents such a review for summarizing the current progress on the manufacturing scalability of electrospun nanofibers and the commercialization of electrospun nanofiber products by dedicated companies globally. Despite the clear potential and limitless possibilities for electrospun nanofiber applications, the uptake of electrospinning by the industry is still limited due to the challenges in the manufacturing and turning of electrospun nanofibers into physical products. The recent developments in the field of electrospinning, such as the prominent nonwoven technology, personal views and the potential path forward for the growth of commercially applied products based on electrospun nanofibers, are also highlighted.

Lignin-Based High-Performance Fibers by Textile Spinning Techniques

As a major component of lignocellulosic biomass, lignin is one of the largest natural resources of biopolymers and, thus, an abundant and renewable raw material for products, such as high-performance fibers for industrial applications. Direct conversion of lignin has long been investigated, but the fiber spinning process for lignin is difficult and the obtained fibers exhibit unsatisfactory mechanical performance mainly due to the amorphous chemical structure, low molecular weight of lignin, and broad molecular weight distribution. Therefore, different textile spinning techniques, modifications of lignin, and incorporation of lignin into polymers have been and are being developed to increase lignin's spinnability and compatibility with existing materials to yield fibers with better mechanical performance. This review presents the latest advances in the textile fabrication techniques, modified lignin-based high-performance fibers, and their potential in the enhancement of the mechanical performance.

A new magnetic melt spinning device for patterned nanofiber

The size and morphology of nanofibers directly determine their application scope and performance, while regular patterned fibers further demonstrate their superior performance in the field of sensors and biomaterials. Melt electrospinning enables controlled deposition of fibers and is currently one of the most important means of preparing patterned fibers. However, due to the existence of high-voltage electric field, melt electrospinning has safety problems such as partial discharge and electric field breakdown, coupled with the charge rejection on the fiber surface, which seriously affects the positioning deposition of fibers and makes it difficult to obtain regular patterned fibers, greatly limiting the application areas and application effects of patterned fibers. Therefore, the improvement and innovation of the spinning process is particularly urgent. Based on material-field model and contradiction matrix of TRIZ theory, the problems of melt electrospinning device are systematically analyzed. The technical conflicts are solved by the inventive principles. A three-dimensional mobile magnetic melt spinning device model is constructed, a magnetic spinning test prototype is developed, and the prototype performance and influencing factors are studied by fiber morphology. The results show the following: (1) Replacing electrostatic fields with permanent magnetic fields can fundamentally avoid safety hazards such as electric field breakdown. (2) The magnetic field force on the molten polymer fluid can generate enough stretching force to overcome the surface tension and form fibers. (3) The fibers are deposited without a whipping instability phase similar to the electrospinning process, allowing easy preparation of regular patterned fibers. (4) The planar motion of the collector creates additional stretching effect on the fibers, which can further reduce the fiber diameter. (5) In magnetic spinning, no external high-voltage power supply is required, enabling the portability of the device. The results of this paper can provide a new method for preparing nanofibers with patterned morphology.

The Investigation of the Structure and Properties of Ozone-Sterilized Nonwoven Biopolymer Materials for Medical Applications

Nowadays, the development and research of nonwoven medical fibrous materials based on biopolymers is an area of a great practical interest. One of the most promising methods for producing nonwoven materials with a highly developed surface is electrospinning (ES). In this article, the possibility of efficient sterilization of ultrathin fibers based on polyhydroxybutyrate (PHB) by ozone treatment was considered. The purpose of this work was to select the most optimal morphology of nonwoven materials for medical purposes and to establish the correlation between the supramolecular structure and the physical properties of fibrous materials while under the influence of an ozone sterilization process.

Electrospinning of small diameter vascular grafts with preferential fiber directions and comparison of their mechanical behavior with native rat aortas

Conventional electrospun small diameter vascular grafts have a random fiber orientation. In order to achieve mechanical characteristics similar to a native blood vessel, a controllable fiber orientation is of interest. In this study the electrospinning jet was directly controlled by means of an auxiliary, changeable electrostatic field, so that the fibers could be deposited in adjustable orientations. Prostheses with circumferentially, axially, fenestrated and randomly aligned fibers were electrospun on Ø2mm mandrels out of a thermoplastic polyurethane (PUR) and a polylactid acid (PLLA). The impact of the materials and the various preferential fiber orientations on the resulting biomechanics was investigated and compared with that of the native rat aorta in quasistatic and dynamic hoop tensile tests. The test protocol included 3000 dynamic loading cycles in the physiological blood pressure range and ended with a quasistatic tensile test. Any orientation of the fibers in a particular direction resulted in a significant reduction in scaffold porosity for both materials. The standard randomly oriented PUR grafts showed the highest compliance of 29.7 ± 5.5 [%/100 mmHg] and were thus closest to the compliance of the rat aortas, which was 37.2 ± 6.5 [%/100 mmHg]. The maximum tensile force was increased at least 6 times compared to randomly spun grafts by orienting the fibers in the circumferential direction. During the 3000 loading cycles, creeping of the native rat aorta was below 1% whereas the electrospun grafts showed creeping up to 2.4 ± 1.2%. Although the preferred fiber orientations were only partially visible in the scanning electron micrographs, the mechanical effects were evident. The investigations suggest a multi-layer wall structure of the vascular prosthesis, since none of the preferred fiber directions and the materials used could imitate the typical j-shaped mechanical characteristics of the rat aorta.

Comparative Analysis of Fiber Alignment Methods in Electrospinning

Fabrication of anisotropic materials is highly desirable in designing biomaterials and tissue engineered constructs. Electrospinning has been broadly adopted due to its versatility in producing non-woven fibrous meshes with tunable fiber diameters (from 10 nanometers to 10 microns), microarchitectures, and construct geometries. A myriad of approaches have been utilized to control fiber alignment of electrospun materials to achieve complex microarchitectures, improve mechanical properties, and provide topographical cellular cues. This review provides a comparative analysis of the techniques developed to generate fiber alignment in electrospun materials. A description of the underlying mechanisms that drive fiber alignment, setup variations for each technique, and the resulting impact on the aligned microarchitecture is provided. A critical analysis of the advantages and limitations of each approach is provided to guide researchers in method selection. Finally, future perspectives of advanced electrospinning methodologies are discussed in terms of developing a scalable method with precise control of microarchitecture.

Scale-up of Electrospinning: Market Overview of Products and Devices for Pharmaceutical and Biomedical Purposes

Recently, the electrospinning (ES) process has been extensively studied due to its potential applications in various fields, particularly pharmaceutical and biomedical purposes. The production rate using typical ES technology is usually around 0.01-1 g/h, which is lower than pharmaceutical industry production requirements. Therefore, different companies have worked to develop electrospinning equipment, technological solutions, and electrospun materials into large-scale production. Different approaches have been explored to scale-up the production mainly by increasing the nanofiber jet through multiple needles, free-surface technologies, and hybrid methods that use an additional energy source. Among them, needleless and centrifugal methods have gained the most attention and applications. Besides, the production rate reached (450 g/h in some cases) makes these methods feasible in the pharmaceutical industry. The present study overviews and compares the most recent ES approaches successfully developed for nanofibers' large-scale production and accompanying challenges with some examples of applied approaches in drug delivery systems. Besides, various types of commercial products and devices released to the markets have been mentioned.

Topographical and Biomechanical Guidance of Electrospun Fibers for Biomedical Applications

Electrospinning is gaining increasing interest in the biomedical field as an eco-friendly and economic technique for production of random and oriented polymeric fibers. The aim of this review was to give an overview of electrospinning potentialities in the production of fibers for biomedical applications with a focus on the possibility to combine biomechanical and topographical stimuli. In fact, selection of the polymer and the eventual surface modification of the fibers allow selection of the proper chemical/biological signal to be administered to the cells. Moreover, a proper design of fiber orientation, dimension, and topography can give the opportunity to drive cell growth also from a spatial standpoint. At this purpose, the review contains a first introduction on potentialities of electrospinning for the obtainment of random and oriented fibers both with synthetic and natural polymers. The biological phenomena which can be guided and promoted by fibers composition and topography are in depth investigated and discussed in the second section of the paper. Finally, the recent strategies developed in the scientific community for the realization of electrospun fibers and for their surface modification for biomedical application are presented and discussed in the last section.

Label-Free Optical Biosensing Using Low-Cost Electrospun Polymeric Nanofibers

Polymeric nanofiber matrices are promising structures to develop biosensing devices due to their easy and affordable large-scale fabrication and their high surface-to-volume ratio. In this work, the suitability of a polyamide 6 nanofiber matrix for the development of a label-free and real-time Fabry–Pérot cavity-based optical biosensor was studied. For such aim, in-flow biofunctionalization of nanofibers with antibodies, bound through a protein A/G layer, and specific biodetection of 10 µg/mL bovine serum albumin (BSA) were carried out. Both processes were successfully monitored via reflectivity measurements in real-time without labels and their reproducibility was demonstrated when different polymeric nanofiber matrices from the same electrospinning batch were employed as transducers. These results demonstrate not only the suitability of correctly biofunctionalized polyamide 6 nanofiber matrices to be employed for real-time and label-free specific biodetection purposes, but also the potential of electrospinning technique to create affordable and easy-to-fabricate at large scale optical transducers with a reproducible performance.

Hydrogel-Assisted Electrospinning for Fabrication of a 3D Complex Tailored Nanofiber Macrostructure

Electrospinning has shown great potential in tissue engineering and regenerative medicine due to a high surface-area-to-volume ratio and an extracellular matrix-mimicking structure of electrospun nanofibers, but the fabrication of a complex three-dimensional (3D) macroscopic configuration with electrospun nanofibers remains challenging. In the present study, we developed a novel hydrogel-assisted electrospinning process (GelES) to fabricate a 3D nanofiber macrostructure with a 3D complex but tailored configuration by utilizing a 3D hydrogel structure as a grounded collector instead of a metal collector in conventional electrospinning. The 3D hydrogel collector was discovered to effectively concentrate the electric field toward itself similar to the metal collector, thereby depositing electrospun nanofibers directly on its exterior surface. Synergistic advantages of the hydrogel (e.g., biocompatibility and thermally reversible sol-gel transition) and the 3D nanofiber macrostructure (e.g., mechanical robustness and high permeability) provided by the GelES process were demonstrated in a highly permeable tubular tissue graft and a robust drug- or cell-encapsulation construct. GelES is expected to broaden potential applications of electrospinning to not only provide in vivo drug/cell delivery and tissue regeneration but also an in vitro drug testing platform by increasing the degree of freedom in the configuration of the 3D nanofiber macrostructure.