Creating tissues from textiles: scalable nonwoven manufacturing techniques for fabrication of tissue engineering scaffolds

Porous Melt Blown Poly(butylene terephthalate) Fibers with High Ductility and High-Temperature Structural Stability

In this study, porous poly(butylene terephthalate) (PBT) fibers were produced by melt blowing cocontinuous blends of PBT and polystyrene (PS) and selectively extracting the interconnected PS domains. Small amounts of hydroxyl terminated PS additives that can undergo transesterification with the ester units in PBT were added to stabilize the cocontinuous structure during melt processing. The resulting fibers are highly ductile and display fine porous structural features, which persist at temperatures over 150 °C. Single fiber tensile testing and electron microscopy are presented to demonstrate the role of rapid quenching and drawing of the melt blowing process in defining the fiber properties. The templated highly aligned pore structure, which is not easily produced in solvent-based fiber spinning methods, leads to remarkable mechanical properties of the porous fibers and overcomes the notoriously poor tensile properties common to other cellular materials like foams.

Surface Modification of PP and PBT Nonwoven Membranes for Enhanced Efficiency in Photocatalytic MB Dye Removal and Antibacterial Activity

In this study, we developed highly efficient nonwoven membranes by modifying the surface of polypropylene (PP) and poly(butylene terephthalate) (PBT) through photo-grafting polymerization. The nonwoven membrane surfaces of PP and PBT were grafted with poly(ethylene glycol) diacrylate (PEGDA) in the presence of benzophenone (BP) and metal salt. We immobilized tertiary amine groups as BP synergists on commercial nonwoven membranes to improve PP and PBT surfaces. In situ Ag, Au, and Au/Ag nanoparticle formation enhances the nonwoven membrane surface. SEM, FTIR, and EDX were used to analyze the surface. We evaluated modified nonwoven membranes for photocatalytic activity by degrading methylene blue (MB) under LED and sunlight. Additionally, we also tested modified membranes for antibacterial activity against E. coli. The results indicated that the modified membranes exhibited superior efficiency in removing MB from water. The PBT showed the highest efficiency in dye removal, and bimetallic nanoparticles were more effective than monometallic. Modified membranes exposed to sunlight had higher efficiency than those exposed to LED light, with the PBT/Au/Ag membrane showing the highest dye removal at 97% within 90 min. The modified membranes showed reuse potential, with dye removal efficiency decreasing from 97% in the first cycle to 85% in the fifth cycle.

Pilot-Scale Melt Electrospinning of Polybutylene Succinate Fiber Mats for a Biobased and Biodegradable Face Mask

The COVID-19 pandemic led to a huge demand for disposable facemasks. Billions were manufactured from nonbiodegradable petroleum-derived polymers, and many were discarded in the environment where they contributed to plastic pollution. There is an urgent need for biobased and biodegradable facemasks to avoid environmental harm during future disease outbreaks. Melt electrospinning is a promising alternative technique for the manufacturing of filter layers using sub-microfibers prepared from biobased raw materials such as polybutylene succinate (PBS). However, it is not yet possible to produce sub-micrometer PBS fibers or uniform nonwoven-like samples at the pilot scale, which hinders their investigation as filter layers. Further optimization of pilot-scale PBS melt electrospinning is therefore required. Here, we tested the effect of different parameters such as electric field strength, nozzle-to-collector distance and throughput on the final fiber diameter and sample uniformity during PBS melt electrospinning on a pilot-scale device. We also studied the effect of a climate chamber and an additional infrared heater on the solidification of PBS fibers and their final diameter and uniformity. In addition, a post-processing step, including a hot air stream of 90 °C for 30 s has been studied and successfully lead to a nonwoven-like structure including filaments that weld together without changing their structure. The finest fibers (1.7 µm in diameter) were produced at an applied electric field strength of -40 kV, a nozzle-to-collector distance of 5.5 cm, and a spin pump speed of 2 rpm. Three uniform nonwoven-like samples were tested as filter layers in a medical face mask by measuring their ability to prevent the transfer of bacteria, but the pore size was too large for effective retention. Our results provide insight into the process parameters influencing the suitability of melt-electrospun nonwoven-like samples as biobased and biodegradable filter materials and offer guidance for further process optimization.

Development of hydroxyapatite-coated nonwovens for efficient isolation of somatic stem cells from adipose tissues

Adipose-derived stem cells (ASCs) are an attractive cell source for cell therapy. Despite the increasing number of clinical applications, the methodology for ASC isolation is not optimized for every individual. In this study, we developed an effective material to stabilize explant cultures from small-fragment adipose tissues.

Methods

Polypropylene/polyethylene nonwoven sheets were coated with hydroxyapatite (HA) particles. Adipose fragments were then placed on these sheets, and their ability to trap tissue was monitored during explant culture. The yield and properties of the cells were compared to those of cells isolated by conventional collagenase digestion.

Results

Hydroxyapatite-coated nonwovens immediately trapped adipose fragments when placed on the sheets. The adhesion was stable even in culture media, leading to cell migration and proliferation from the tissue along with the nonwoven fibers. A higher fiber density further enhanced cell growth. Although cells on nonwoven explants could not be fully collected with cell dissociation enzymes, the cell yield was significantly higher than that of conventional monolayer culture without impacting stem cell properties.

Conclusions

Hydroxyapatite-coated nonwovens are useful for the effective primary explant culture of connective tissues without enzymatic cell dissociation.

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Hydroxyapatite-coated nonwovens enable explant culture of adipose tissue.

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ASCs migrated and proliferated from the tissue explants along the fibers in nonwovens.

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Nonwoven explants had significantly higher cell yield than conventional culture.

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Nonwoven culture did not impact stem cell properties of ASCs.

The Influence of Surface Modification with Biopolymers on the Structure of Melt-Blown and Spun-Bonded Poly(lactic acid) Nonwovens

The article presents the continuation of the research on modification of fibrous carriers based on poly(lactic acid) using the electrophoretic deposition (EPD) method by the two types of biocompatible polymers-sodium hyaluronate and sodium alginate. Such modified nonwovens, differing in the structural parameters due to different manufacturing methods, could be potentially used in different biomedical applications. The results of the analysis indicate that the EPD process significantly changes the structural characteristics of the carrier in terms of thickness and porosity, which not always can be beneficial in terms of the final application. The varying structure of both carriers significantly influences the mode of deposition of the layer, the efficiency of the deposition process as well as the structural characteristics of the carrier after deposition. Microtomographic and SEM studies were employed to analyze the structure of deposits, and FTIR analysis allowed for confirmation of the occurrence of the polymer layers and its chemical structure.

Multiphase CFD Modeling and Experimental Validation of Polymer and Attenuating Air Jet Interactions in Nonwoven Annular Melt Blowing

In annular melt blowing, fiber formation is achieved by accelerating a molten polymer via drag forces imparted by high velocity air that attenuates the polymer jet diameter. The interactions at the polymer-air interface, which govern the motion of the jets and impact the resulting fiber characteristics, are important but not well understood yet. This work details the development and validation of a multiphase computational fluid dynamics (CFD) model to investigate these interactions and the effects of three key melt blowing process parameters (polymer viscosity and throughput, and air velocity) on two critical fiber attributes - whipping instability and fiber diameter. Simulation results highlighted that whipping instability was driven by the polymer-air velocity differential, and the fiber diameter was primarily modulated by polymer throughput and air velocity. The CFD model was validated by modulating the polymer and air throughputs and analyzing the fiber diameter experimentally. Empirical results showed good agreement between fabricated and model-estimated fiber diameters, especially at lower air velocities. An additional CFD simulation performed using a melt blowing nozzle geometry and process parameters described in literature also confirmed good correlation between model estimates and literature empirical data.

Droplet-based bioprinting enables the fabrication of cell–hydrogel–microfibre composite tissue precursors

Composites offer the option of coupling the individual benefits of their constituents to achieve unique material properties, which can be of extra value in many tissue engineering applications. Strategies combining hydrogels with fibre-based scaffolds can create tissue constructs with enhanced biological and structural functionality. However, developing efficient and scalable approaches to manufacture such composites is challenging. Here, we use a droplet-based bioprinting system called reactive jet impingement (ReJI) to integrate a cell-laden hydrogel with a microfibrous mesh. This system uses microvalves connected to different bioink reservoirs and directed to continuously jet bioink droplets at one another in mid-air, where the droplets react and form a hydrogel that lands on a microfibrous mesh. Cell–hydrogel–fibre composites are produced by embedding human dermal fibroblasts at two different concentrations (5 × 106 and 30 × 106 cells/mL) in a collagen–alginate–fibrin hydrogel matrix and bioprinted onto a fibre-based substrate. Our results show that both types of cell–hydrogel–microfibre composite maintain high cell viability and promote cell–cell and cell–biomaterial interactions. The lower fibroblast density triggers cell proliferation, whereas the higher fibroblast density facilitates faster cellular organisation and infiltration into the microfibres. Additionally, the fibrous component of the composite is characterised by high swelling properties and the quick release of calcium ions. The data indicate that the created composite constructs offer an efficient way to create highly functional tissue precursors for laminar tissue engineering, particularly for wound healing and skin tissue engineering applications.

Graphic abstract

Attachment of Tragacanth gum on polyester fabric through the synthesis of iron oxide gaining novel biological, physical, and thermal features

This study focuses on polyester fabric modification to produce environmentally-friendly multifunctional fabrics for varied applications. The nanoparticles of iron oxide were achieved from ferrous sulfate solution under alkaline conditions and applied to Tragacanth gum to form an efficient layer on the polyester surface. The synthesis of Fe₃O₄ nanoparticles with a crystal size of 12 nm was approved in the XRD spectra and iron oxide/Tragacanth gum nanocomposites with an agglomerated size of about 62 nm were confirmed by the SEM and EDX techniques. The formation of hydroxyl and iron oxide bands was observed in the FTIR and XPS patterns. The superparamagnetic behavior of treated samples exhibited by VSM with a magnetic saturation of 0.86 emu/g. The products showed an antibacterial activity (95 and 91%) toward Gram-positive and -negative bacteria. The absorbance intensity of methylene blue decreased from 2.6 to 1.6 by the treated sample. The synthesized nanoparticles on the treated surface indicated a lower release of iron ions and cell toxicity. The rate of cell duplication increased under a magnetic field with 60 Hz and 0.5 mT for 20 min/day. The product color changed from white to a brownish hue and the wetting capacity and thermal ability increased.

Special Features of Polyester-Based Materials for Medical Applications

This article presents current possibilities of using polyester-based materials in hard and soft tissue engineering, wound dressings, surgical implants, vascular reconstructive surgery, ophthalmology, and other medical applications. The review summarizes the recent literature on the key features of processing methods and potential suitable combinations of polyester-based materials with improved physicochemical and biological properties that meet the specific requirements for selected medical fields. The polyester materials used in multiresistant infection prevention, including during the COVID-19 pandemic, as well as aspects covering environmental concerns, current risks and limitations, and potential future directions are also addressed. Depending on the different features of polyester types, as well as their specific medical applications, it can be generally estimated that 25–50% polyesters are used in the medical field, while an increase of at least 20% has been achieved since the COVID-19 pandemic started. The remaining percentage is provided by other types of natural or synthetic polymers; i.e., 25% polyolefins in personal protection equipment (PPE).

Fabrication of Biomedical Scaffolds Using Biodegradable Polymers

Degradable polymers are used widely in tissue engineering and regenerative medicine. Maturing capabilities in additive manufacturing coupled with advances in orthogonal chemical functionalization methodologies have enabled a rapid evolution of defect-specific form factors and strategies for designing and creating bioactive scaffolds. However, these defect-specific scaffolds, especially when utilizing degradable polymers as the base material, present processing challenges that are distinct and unique from other classes of materials. The goal of this review is to provide a guide for the fabrication of biodegradable polymer-based scaffolds that includes the complete pathway starting from selecting materials, choosing the correct fabrication method, and considering the requirements for tissue specific applications of the scaffold.

Trends in Surgical and Beauty Masks for a Cleaner Environment

The surgical face mask (SFM) is a sheet medical device covering the mouth, nose and chin to protect the medical staff from the spread of respiratory droplets produced by the infective coughing or sneezing of hospitalized patients. On the other hand the beauty face mask (BFM) has been made by the same sheet but with a different aim—to protect the skin from pollution, acting as a hydrating and rejuvenation agent. Currently, both masks are made principally by non-biodegradable tissues, utilized to avoid the increasing great pollution invading our planet. Due to the diffusion of the current COVID-19 infection rate and the increasing consumption of skin care and beauty products, the waste of these masks, made principally by petrol-derived polymers, is creating further intolerable waste-invaded land and oceans. After an introduction to the aims, differences and market of the various masks, their productive means and ingredients are reported. These news are believed necessary to give the reader the working knowledge of these products, in the context of the bioeconomy, to better understand the innovative tissues proposed and realized by the biobased and biodegradable polymers. Thus, the possibility of producing biodegradable SFMs and BFMs, characterized for their effective antimicrobial and skin repairing activities or hydrating and antiaging activity, respectively. These innovative smart and biodegradable masks are requested from the majority of consumers oriented towards a future green environment. Giving this new sense of direction to their production and consumption, it will be possible to reduce the current waste, ranging worldwide at about 2 billion tons per year.

A solution blown superporous nonwoven hydrogel based on hydroxypropyl cellulose

A superporous hydrogel - in which the interconnecting fibres themselves are hydrogels - based on hydroxypropyl cellulose (HPC) has been produced using the nonwoven solution blown technique. The nonwoven fibres were subsequently thermally crosslinked with citric acid as identified by esterbond formation using FT-IR spectroscopy. The gel fraction was approximately 70%. The superporous HPC hydrogel exhibited a very fast water absorption, reaching an equilibrium absorption (80% water content) within 30 seconds. The equilibrium absorption was strongly codependent on both the fibre thickness and the pore size whereas the absorption rate was correlated with the pore size as established using standard linearized regression analysis.

High-Throughput Manufacture of 3D Fiber Scaffolds for Regenerative Medicine

Engineered scaffolds used to regenerate mammalian tissues should recapitulate the underlying fibrous architecture of native tissue to achieve comparable function. Current fibrous scaffold fabrication processes, such as electrospinning and three-dimensional (3D) printing, possess application-specific advantages, but they are limited either by achievable fiber sizes and pore resolution, processing efficiency, or architectural control in three dimensions. As such, a gap exists in efficiently producing clinically relevant, anatomically sized scaffolds comprising fibers in the 1-100 μm range that are highly organized. This study introduces a new high-throughput, additive fibrous scaffold fabrication process, designated in this study as 3D melt blowing (3DMB). The 3DMB system described in this study is modified from larger nonwovens manufacturing machinery to accommodate the lower volume, high-cost polymers used for tissue engineering and implantable biomedical devices and has a fiber collection component that uses adaptable robotics to create scaffolds with predetermined geometries. The fundamental process principles, system design, and key parameters are described, and two examples of the capabilities to create scaffolds for biomedical engineering applications are demonstrated. Impact statement Three-dimensional melt blowing (3DMB) is a new, high-throughput, additive manufacturing process to produce scaffolds composed of highly organized fibers in the anatomically relevant 1-100 μm range. Unlike conventional melt-blowing systems, the 3DMB process is configured for efficient use with the relatively expensive polymers necessary for biomedical applications, decreasing the required amounts of material for processing while achieving high throughputs compared with 3D printing or electrospinning. The 3DMB is demonstrated to make scaffolds composed of multiple fiber materials and organized into complex shapes, including those typical of human body parts.

Synthetic scaffolds for musculoskeletal tissue engineering: cellular responses to fiber parameters

Tissue engineering often uses synthetic scaffolds to direct cell responses during engineered tissue development. Since cells reside within specific niches of the extracellular matrix, it is important to understand how the matrix guides cell response and then incorporate this knowledge into scaffold design. The goal of this review is to review elements of cell-matrix interactions that are critical to informing and evaluating cellular response on synthetic scaffolds. Therefore, this review examines fibrous proteins of the extracellular matrix and their effects on cell behavior, followed by a discussion of the cellular responses elicited by fiber diameter, alignment, and scaffold porosity of two dimensional (2D) and three dimensional (3D) synthetic scaffolds. Variations in fiber diameter, alignment, and scaffold porosity guide stem cells toward different lineages. Cells generally exhibit rounded morphology on nanofibers, randomly oriented fibers, and low-porosity scaffolds. Conversely, cells exhibit elongated, spindle-shaped morphology on microfibers, aligned fibers, and high-porosity scaffolds. Cells migrate with higher velocities on nanofibers, aligned fibers, and high-porosity scaffolds but migrate greater distances on microfibers, aligned fibers, and highly porous scaffolds. Incorporating relevant biomimetic factors into synthetic scaffolds destined for specific tissue application could take advantage of and further enhance these responses.

Nonwoven membranes for tissue engineering: an overview of cartilage, epithelium, and bone regeneration

Scaffold-type biomaterials are crucial for application in tissue engineering. Among them, the use of a nonwoven scaffold has grown in recent years and has been widely investigated for the regeneration of different types of tissues. Several polymers, whether they are synthetic, biopolymers or both, have been used to produce a scaffold that can mimic the natural tissue to which it will be applied to. The scaffolds used in tissue engineering must be biocompatible and allow cell adhesion and proliferation to be applied in tissue engineering. In addition, the scaffolds should maintain the mechanical properties and architecture of the desired tissue. Nonwoven fabrics have produced good results and are more extensively applied for the regeneration of cartilage, epithelial and bone tissues. Recent advances in tissue engineering have shown promising results, however, no ideal material or standardization parameters and characteristics of the materials were obtained. The present review provides an overview of the application of nonwoven scaffolds, including the main results obtained regarding the properties of the biomaterials and their applications in vitro and in vivo, focusing on the cartilaginous, the epithelium, and bone tissue regeneration.

A simplified fabrication technique for cellularized high-collagen dermal equivalents

Human autologous bioengineered skin has been successfully developed and used to treat skin injuries in a growing number of cases. In current clinical studies, the biomaterial used is fabricated via plastic compression of collagen hydrogel to increase the density and stability of the tissue. To further facilitate clinical adoption of bioengineered skin, the fabrication technique needs to be improved in terms of standardization and automation. Here, we present a one-step mixing technique using highly concentrated collagen and human fibroblasts to simplify fabrication of stable dermal equivalents. As controls, we prepared cellularized dermal equivalents with three varying collagen compositions. We found that the dermal equivalents produced using the simplified mixing technique were stable and pliable, showed viable fibroblast distribution throughout the tissue, and were comparable to highly concentrated manually produced collagen gels. Because no subsequent plastic compression of collagen is required in the simplified mixing technique, the fabrication steps and production time for dermal equivalents are consistently reduced. The present study provides a basis for further investigations to optimize the technique, which has significant promise in enabling efficient clinical production of bioengineered skin in the future.

* Meltblown Polymer Fabrics as Candidate Scaffolds for Rotator Cuff Tendon Tissue Engineering

Various biomaterial technologies are promising for tissue engineering, including electrospinning, but commercial scale-up of throughput is difficult. The goal of the study was to evaluate meltblown fabrics as candidate scaffolds for rotator cuff tendon tissue engineering. Meltblown poly(lactic acid) fabrics were produced with several polymer crystallinities and airflow velocities [500(low), 900(medium) or 1400(high) m³air/h/m fabric]. Fiber diameter, alignment, and baseline bidirectional tensile mechanical properties were evaluated. Attachment and spreading of human adipose-derived stem cells (hASCs) were evaluated over 3 days immediately following seeding. After initial screening, the fabric with the greatest Young's modulus and yield stress was selected for 28-day in vitro culture and for evaluation of tendon-like extracellular matrix production and development of mechanical properties. As expected, airflow velocity of the polymer during meltblowing demonstrated an inverse relationship with fiber diameter. All fabrics exhibited fiber alignment parallel to the direction of collector rotation. All fabrics demonstrated mechanical anisotropy at baseline. Cells attached, proliferated, and spread on all fabrics over the initial three-day culture period. Consistent with the observed loss of integrity of the unseeded biomaterial, hASC-seeded scaffolds demonstrated a significant decrease in Young's modulus over 28 days of culture. However, dsDNA, sulfated glycosaminoglycan, and collagen content increased significantly over 28 days. Histology and polarized light microscopy demonstrated collagen deposition and alignment throughout the thickness of the scaffolds. While fiber diameters approximated an order of magnitude greater than those previously reported for electrospun scaffolds intended for tendon tissue engineering, they were still within the range of collagen fiber diameters found in healthy tendon. The extent of matrix production and alignment was similar to that previously observed for multilayered electrospun scaffolds. While the Young's modulus of scaffolds after 28 days of culture was lower than native rotator cuff tendon, it approximated that reported previously following culture of electrospun scaffolds and was on the same order of magnitude as of current Food and Drug Administration-approved patches for rotator cuff augmentation. Together, these data suggest that with minor polymer and parameter modifications, meltblown scaffolds could provide an economical, high-throughput production alternative method to electrospinning for use in rotator cuff tendon tissue engineering.