Melt electrospun fibers of poly(ϵ-caprolactone) are accurately deposited using an automated stage as the collector. Matching the translation speed of the collector to the speed of the melt electrospinning jet establishes control over the location of fiber deposition. In this sense, melt electrospinning writing can be seen to bridge the gap between solution electrospinning and direct writing additive manufacturing processes.

Direct writing by way of melt electrospinning

Electrospinning is a straightforward and versatile method to fabricate ultrafine fibers with unique physical and chemical properties. However, the chaotic nature of traditional electrospinning limits its applications in devices which usually need arranged or patterned micro/nanoscale fibrous structures. In order to improve the controllable deposition of electrospun fibers, near-field electrospinning (NFES) has been proposed and developed in recent years. With characteristics of position-controlled deposition, NFES significantly expands the range of fiber-fabrication uses including electronic components, energy harvesting, flexible sensors, and tissue engineering. In this paper, the basic principle and research advances of NFES have been briefly reviewed. In particular, we summarize the process parameters, polymer materials, as-spun fibrous structures, modified apparatus, and potential applications of NFES. Finally, future prospects on the development tendency and challenges of NFES are discussed.

Near-Field Electrospinning: Progress and Applications

Additive manufacturing technologies based on layer-by-layer deposition of material ejected from a nozzle provide unmatched versatility but are limited in terms of printing speed and resolution. Electrohydrodynamic jetting uniquely allows generating submicrometer jets that can reach speeds above 1 m s−1, but such jets cannot be precisely collected by too slow mechanical stages. Here, we demonstrate that controlling the voltage applied to electrodes located around the jet, its trajectory can be continuously adjusted with lateral accelerations up to 106 m s−2. Through electrostatically deflecting the jet, 3D objects with submicrometer features can be printed by stacking nanofibers on top of each other at layer-by-layer frequencies as high as 2000 Hz. The fast jet speed and large layer-by-layer frequencies achieved translate into printing speeds up to 0.5 m s−1 in-plane and 0.4 mm s−1 in the vertical direction, three to four orders of magnitude faster than techniques providing equivalent feature sizes. Additive manufacturing technologies provide versatility but are limited in terms of printing speed and resolution. Here the authors demonstrate printing of 3D structures with submicrometer features by electrostatically deflecting a jet in electrohydrodynamic jetting.

/pdf/ultrafast-3d-printing-with-submicrometer-features-using-4hk0nxr6og.pdf

Ultrafast 3D printing with submicrometer features using electrostatic jet deflection.

The extracellular matrix (ECM) is known to play an important role in the health of cells and tissues. Not only are chemical signals transmitted via bonds and tightly controlled diffusion, but the structure of the ECM also provides important physical signaling for the cells attached to it. The structure is composed of a mesh of fibrous proteins, such as collagen, embedded in a hydrated gel matrix of glycosaminoglycans. To study cell behavior with respect to the combined morphology and mechanics of such matrices is not currently possible with the types of 3D cell culture matrices available. Most of the cell culture matrices are single-phase bio- or polymeric hydrogels. Therefore, here we developed a continuous hybrid manufacturing process to make fiber-reinforced composite hydrogels. A far field electrospinning process was used to deposit the fibrous component with the aid of guiding electrodes; and a gravity-assisted, droplet-based system controlled the rate of addition of the cell-laden hydrogel component. The addition of the fibrous component slightly increased the elastic modulus of the pure hydrogel. The cells that were embedded into the fiber-reinforced hydrogels were viable for 8 days. The cells were randomly placed in the matrix such that some had no contact to the fibers and others were initially in proximity to fibers. The cells with no contact to fibers grew into spheroidal clusters within the hydrogel, and those in proximity to the fibers spread out and grew along the fibers showing that the fiber-reinforced hydrogels are able to control cell behavior with morphological cues.

/pdf/toward-morphologically-relevant-extracellular-matrix-in-4idicis21q.pdf

Toward Morphologically Relevant Extracellular Matrix in Vitro Models: 3D Fiber Reinforced Hydrogels.

The extracellular matrix (ECM) contains nanofibrous proteins and proteoglycans. Nanofabrication methods have received growing interest in recent years as a means of recapitulating these elements within the ECM. Near-field electrospinning (NFES) is a versatile fibre deposition method, capable of layer-by-layer nano-fabrication. The maximum layer height is generally limited in layer-by-layer NFES as a consequence of electrostatic effects of the polymer at the surface, due to residual charge and polymer dielectric properties. This restricts the total volume achievable by layer-by-layer techniques. Surpassing this restriction presents a complex challenge, leading to research innovations aimed at increasing patterning precision, and achieving a translation from 2D to 3D additive nanofabrication. Here we investigated a means of achieving this translation through the use of 3D electrode substrates. This was addressed by in-house developed technology in which selective laser melt manufactured standing pillar electrodes were combined with a direct suspension near-field electrospinning (SNFES) technique, which implements an automated platform to manoeuvre the pillar electrodes around the emitter in order to suspend fibres in the free space between the electrode support structures. In this study SNFES was used in multiple operation modes, investigating the effects of varying process parameters, as well as pattern variations on the suspended nanoarrays. Image analysis of the nanoarrays allowed for the assessment of fibre directionality, isotropy, and diameter; identifying optimal settings to generate fibres for tissue engineering applications.

/pdf/patterning-and-process-parameter-effects-in-3d-suspension-1gh7k3djy1.pdf

Patterning and process parameter effects in 3D suspension near-field electrospinning of nanoarrays

Feasibility of Fiber-Deposition Control by Secondary Electric Fields in Near-Field Electrospinning

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Feasibility of Fiber-Deposition Control by Secondary Electric Fields in Near-Field Electrospinning