In this case study, we examine how Atreon Orthopedics leveraged electrospinning technology to develop ROTIUM® Bioresorbable Wick — an advanced synthetic scaffold engineered to improve tendon-to-bone healing and support biologic tissue remodeling in orthopedic repair procedures.

Challenge

Rotator cuff repair remains challenging because the tendon-bone interface often does not provide an optimal biologic environment for healing. Atreon Orthopedics set out to address that gap with a solution that could support the healing cascade while integrating easily into standard surgical workflows.

Solution

Atreon Orthopedics developed ROTIUM® Bioresorbable Wick, an interpositional scaffold placed at the tendon-bone interface. The product is 100% synthetic and built with PGA and PLCL, and it is designed to supercharge the biologic environment, support tissue remodeling, and improve long-term outcomes after rotator cuff repair.
Using Fluidnatek electrospinning technology, Atreon can produce reproducible synthetic nanofiber scaffolds with the process control needed for development and manufacturing.

“We use the Fluidnatek LE-500 system in the R&D and manufacturing of most of our products. I have over 20 years of electrospinning experience and am very pleased with the ease of use, consistency of product, and the manufacturing output of the Fluidnatek LE-500 system. The high voltage and multiple voltage sources play a critical part in our manufacturing process. Our electrospun scaffolds have been used in over 20,000 surgeries to date and our fantastic outcomes for our patients are powered by the Fluidnatek systems.” — Jed Johnson, CTO of Atreon Orthopedics.

Results

ROTIUM has been used in more than 10,000 rotator cuff repair surgeries, and Atreon later received FDA 510(k) clearance to expand the indications to tendon repair surgeries.
Atreon reports that the scaffold supports repair at the critical tendon-bone interface and integrates seamlessly into standard surgical technique without adding surgical time.
The result is a clinically adopted bioresorbable scaffold platform that has helped Atreon broaden its regenerative orthopedic offering.

Want to develop advanced biomaterials with Fluidnatek? Let’s talk!
contact@fluidnatek.com +34 674071303

In this case study, we explore how MARILYS Blanchy, Expert in Materials for Medical Devices at APPLUS/RESCOLL, addressed the challenges of developing advanced biomimetic scaffolds for bone regeneration using our electrospinning technology.

Challenge

“In our quest to create advanced biomimetic scaffolds, we faced a significant challenge: reproducing fully functional and vascularized tissue. These scaffolds serve as templates, enabling endogenous tissue to reconstruct or regenerate effectively.”

Solution

To address these needs, APPLUS/RESCOLL developed a multi-material, multiscale approach that combines a 3D scaffold for mechanical support with an electrospun membrane designed as a drug reservoir and cell-interactive interface. They used a Fluidnatek LE-100 electrospinning system to fine-tune fiber morphology, scaffold architecture and release behavior.

Marilys Blanchy: “With Fluidnatek LE-100 we can control the environment (temperature and relative humidity), we have two sources of high voltage, different geometries of collectors (rotating or flat), and we can fine-tune the flow rate and the line displacement of the nozzle during the manufacturing process.”

Specifications used:

• Temperature 20 – 50° C
• Relative humidity 10 -90%
• 2 High voltage : 0 – 30 kV et -30-0 kV
• Rotating collector : 2 diameter 18mm et 100mm v=0-2000 rpm
• Flat collector ; 40*40 cm
• Max-min flow rates: 1.257-0,73 ml/h
• 2 syringues pumpes heated up to 120°C
• X motion : 0-100 mm/s

Using these capabilities, the team:

• Adjusted process and environmental parameters, such as relative humidity, to modify fiber quality, overall thickness, porosity and patch density.
• Targeted fiber diameters of approximately 1–2 micrometers and patch thicknesses in the 500 micrometer to 1 millimeter range, then verified these values experimentally.
• Characterized and improved surface wettability, starting from a highly hydrophobic matrix with a contact angle around 130°, working on surface state to obtain a more hydrophilic membrane favorable to cell attachment.
• Produced core–shell fibers using two polymer solutions, achieving cores of around 60 nanometers and shells of about 120–200 nanometers, as confirmed by transmission electron microscopy.
• Evaluated the release kinetics of a model molecule (calcine) from the electrospun fibers and showed that, although the overall release profiles were similar, the total amount released could be tuned by changing electrospinning process parameters.

Results

By combining controlled electrospinning with careful materials and process optimization, APPLUS/RESCOLL demonstrated that they could:

• Manufacture electrospun matrices with defined fiber diameter, thickness, porosity and density that are suitable for tissue engineering applications.
• Modify surface hydrophilicity to better support cell attachment and integration.
• Generate reproducible core–shell fibers capable of encapsulating active ingredients in liposomal form and enabling tunable release amounts over time.
• Work towards scalable, batch-to-batch consistent production using medical-grade materials, while studying sterilization conditions to preserve the properties of both the fibers and the incorporated actives.

“Electrospinning has proven to be a game-changer in our research, pushing the boundaries of what’s possible in tissue engineering.” Marilys Blanchy.

In this case study, we explore how the Matrihealth team is tackling the challenge of chronic wounds and scar formation by developing next-generation elastin-based nanofiber scaffolds using electrospinning.

Challenge

Chronic wounds cause immense suffering for patients and represent a growing burden for healthcare systems. Our goal was to design biomimetic materials that restore skin function by mimicking the elastin-rich extracellular matrix.

Solution

Elastin-based nanofiber materials
→ Up to 90% elastin content
→ Sourced from food industry byproducts (sustainable)
→ Biomimetic = mimics native ECM

Results

Matrihealth achieved significant results by:

Building Elastin-Rich Biomimetic Scaffolds: They isolated elastin from food-industry byproducts and incorporated it into electrospun nonwovens in high amounts (up to 90%), creating materials that closely resemble the native extracellular matrix. The scaffolds were then chemically crosslinked to optimize mechanical stability and degradation kinetics.

Tuning Mechanical Properties for Wound Healing: By varying collagen-to-elastin ratios, they precisely adjusted stiffness and porosity, obtaining highly elastic, fully degradable scaffolds ideal for advanced wound care applications.

Validating Biocompatibility and Safety: Extensive testing—including cytocompatibility, endotoxin levels, irritation potential, tensile testing and in vivo studies—demonstrated low irritative potential, excellent cell support and no adverse tissue reactions after implantation.

Enabling Industrial-Scale, Cost-Effective Production: Using an industrially scalable electrospinning process, Matrihealth built a versatile platform for producing elastin-based nonwovens at scale, opening the door to a new generation of absorbable, protein-based wound dressings and other biomedical products.

“From our perspective, the Fluidnatek LE-50 system played a key role in the development of the electrospun material. Its simple and reliable setup enabled rapid optimization of the material system, allowing us to efficiently adjust processing parameters and iterate on formulations within a short time.

In addition, the high flexibility of the system was particularly valuable. The possibility to switch between different configurations such as single- and multi-nozzle setups, as well as drum and plate collectors allowed us to tailor the process conditions to the specific requirements of the material and target structure.

Another important aspect was the ability to produce highly homogeneous fiber mats. This was largely facilitated by the Sweeping X Unit, which ensured uniform fiber deposition. Such homogeneity was essential for obtaining reproducible results and for conducting microstructural and mechanical characterization of the material.

Furthermore, the system represents an “all-in-one” solution for development work. It not only supports classical R&D activities but also provides sufficient capacity to produce material at a small pilot scale. In our case, this enabled us to generate enough material for subsequent in vivo testing, ensuring a seamless transition from development to application.” Tobias Hedtke, CTO at Matrihealth Germany.

If you’re interested in developing your own advanced wound care or biomaterials projects with Fluidnatek’s electrospinning platforms, feel free to reach out—we’re here to help you turn your concepts into patient-ready solutions.