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Biomedical

Cancer Detection and Diagnosis Using Electrospun Fibers

Posted on May 15, 2025May 22, 2025 by Vicente Zaragozá

15
May

The early detection and accurate diagnosis of cancer remain critical challenges in modern healthcare. Despite technological advances, many cancers are still diagnosed at late stages, compromising treatment effectiveness and patient survival rates. But electrospun fibers have a lot to say on this subject.

Among the innovative technologies being developed, electrospun fibers have emerged as revolutionary materials for creating highly sensitive biosensors and diagnostic platforms.

This article explores how electrospun nanofibers are transforming cancer detection through enhanced sensitivity, specificity, and rapid response times.

Electrospun Fibers: What They Are and How They Work

Electrospun fibers are ultrafine filaments produced through a versatile technique called electrospinning, which utilizes electrical forces to draw charged threads from polymer solutions or melts. The resulting fibers typically have diameters ranging from nanometers to micrometers, creating materials with exceptional characteristics due to their resemblance to human tissues, ideal for biomedical applications, particularly cancer biosensing.

The electrospinning process involves:

A polymer solution loaded into a syringe with a metal needle
One or more high-voltage power supplies (typically 5-30 kV)
A grounded or negatively charged collector plate or rotating mandrel
Precise environmental control (temperature, humidity)

When voltage is applied, the polymer solution becomes charged, and when electrostatic repulsion overcomes surface tension, a jet erupts from the needle tip. As this jet travels toward the collector, the solvent evaporates, leaving behind solid polymer fibers that form a non-woven mesh or membrane.

These electrospun nanofibers exhibit several key properties that make them exceptional for cancer detection:

Extremely high surface-to-volume ratio, enhancing biomarker capture efficiency
Tunable porosity for controlled molecular interactions
Customizable fiber diameter and orientation
Ability to incorporate functional materials (antibodies, enzymes, nanoparticles)
Three-dimensional architecture that mimics the extracellular matrix (ECM)

Fluidnatek’s electrospinning technology enables precise adjustment of fiber diameter, porosity, and surface chemistry—attributes crucial for creating effective biosensors that are sensitive, cost-effective, and suitable for point-of-care testing.

Applications of Electrospun Fibers in Cancer Detection

The versatility of electrospun fibers has enabled their integration into multiple cancer detection platforms. These applications leverage the unique structural and functional properties of nanofibers to identify cancer biomarkers with unprecedented sensitivity.

Some of these applications include:

Electrospun Nanofiber Scaffolds for Cancer Cell Detection

Early detection of cancer cells can dramatically improve patient outcomes. Traditional diagnostic methods often lack the sensitivity to detect low-abundance biomarkers in bodily fluids. Electrospun nanofibers address this limitation by providing:

A three-dimensional architecture that mimics the extracellular matrix (ECM), supporting cell adhesion and growth
The ability to be functionalized with biomolecular probes (such as antibodies or aptamers) for high selectivity toward cancer-specific markers

For instance, studies have demonstrated that nanofiber membranes functionalized with prostate-specific membrane antigen (PSMA)-targeted ligands can selectively capture prostate cancer cells from mixed populations. These captured cells can then be analyzed using fluorescence imaging or molecular assays, resulting in improved detection speed and accuracy compared to conventional methods.

Fluorescence pictures of cancer biomarkers on electrospun PS substrates obtained by an inverted fluorescence microscope (200×). (A) AFP (DyLight 488, green), (B) CEA (DyLight 405, blue), (C) VEGF (DyLight 649, red); (a-c) light field, (d-f) fluorescence field, (g-i) superposition view of the two fields. Wang et al (2013) PLoS ONE 2013; 8(12): e82888.

Functionalization Strategies for Selective Detection

Functionalizing electrospun membranes is essential for selective cancer cell detection. Several techniques have proven effective:

Surface Chemistry Engineering: Methods such as plasma treatment, chemical grafting, and layer-by-layer deposition provide precise control over surface properties. For instance, membranes modified with antibodies against PSMA show high specificity for prostate cancer cells.
Multiplexed Detection: Advanced approaches integrate multiple biomarkers onto a single electrospun membrane, enabling simultaneous detection of various cancer types. This multiplexing is particularly valuable when cancer markers overlap across different tumor types, enhancing diagnostic accuracy.

Integration into Microfluidic Systems

Combining electrospun nanofibers with microfluidic chips allows for the development of compact diagnostic devices capable of real-time cancer monitoring. These lab-on-a-chip systems integrate sample processing, detection, and data analysis, making them ideal for point-of-care applications in clinical settings or resource-limited environments.

Case Studies and Recent Advances

Circulating Tumor Cell Capture Using Electrospun Platforms

CTCs, (Circulating tumor cells) are cancer cells that detach from primary tumors and enter the bloodstream, playing a critical role in the metastatic spread of cancer. Their detection and isolation offer valuable insights for early diagnosis, prognosis, and personalized treatment strategies. Electrospun fiber meshes, particularly when functionalized with tumor-specific antibodies (such as anti-EpCAM), have demonstrated remarkable efficiency in capturing these rare cells directly from blood samples.

The unique architecture of electrospun nanofibers—featuring high surface-area-to-volume ratios, tunable porosity, and a 3D interconnected structure—creates an optimal microenvironment for cell capture. These characteristics enable greater interaction between the fibers and flowing blood, increasing the likelihood of CTC adhesion. Recent studies have shown that well-engineered electrospun platforms can achieve capture rates exceeding 90%, significantly outperforming conventional flat-surface or microfluidic-based systems. In one of them, published by Lab on a Chip by Chen, L., et al. (2017), the researchers developed a microfluidic device integrated with electrospun poly (lactic-co-glycolic acid) (PLGA) nanofibers functionalized with anti-EpCAM antibodies.

The high surface area and 3D structure of the nanofibers significantly enhanced the contact between the target cells and the capture surface. The platform achieved capture efficiencies above 90% for EpCAM-positive CTCs in spiked blood samples. The system also maintained high viability of captured cells, enabling downstream analysis.

Functionalization plays a key role in the capture mechanism: antibodies or aptamers immobilized on the nanofiber surfaces selectively bind to antigens expressed on CTC membranes. As blood flows through or across the fibrous mat, CTCs are selectively retained, while most normal blood cells pass through. This specificity and efficiency make electrospun platforms highly promising for liquid biopsy applications and real-time cancer monitoring.

Applications in Liquid Biopsy

Liquid biopsy, a minimally invasive technique analyzing biomarkers from blood, is transforming cancer diagnostics. Electrospun fibers enhance this approach by serving as solid-phase platforms to capture rare cancer cells or exosomes from complex fluids.

A groundbreaking study published in PLoS ONE by Wang et al. (2013) demonstrated the use of electrospun polystyrene (PS) substrates for detecting multiple cancer biomarkers simultaneously. The researchers successfully detected alpha-fetoprotein (AFP), carcinoembryonic antigen (CEA), and vascular endothelial growth factor (VEGF) using fluorescence microscopy on functionalized nanofiber scaffolds, showing the potential for multiplexed cancer detection on a single platform.

Multi-Biomarker Detection Systems

Recent advances in electrospinning for cancer detection have led to the development of systems capable of detecting multiple biomarkers simultaneously. For example, researchers have created electrospun polyacrylonitrile (PAN) fibers functionalized with different antibodies that can detect breast cancer markers like HER2, ER, and PR from a single sample, enabling more accurate subtyping of breast cancers.

Smart Responsive Nanofibers

“Smart” responsive materials have been incorporated into electrospun nanofibers to create visual detection systems. A notable example is the development of pH-responsive polymeric nanofibers that change color in the presence of metabolic byproducts from cancer cells, enabling naked-eye detection without sophisticated equipment.

Advantages of Electrospun Fibers Over Other Cancer Detection Technologies

We must emphasize that electrospun nanofibers offer several significant advantages over conventional cancer detection technologies:

Enhanced Sensitivity and Lower Detection Limits

The high surface-to-volume ratio of electrospun fibers dramatically increases the density of biorecognition elements, improving sensitivity. Comparative studies show that electrospun membranes outperform traditional diagnostic materials such as flat films or hydrogels in several ways:

Faster cell capture kinetics
Improved detection limits (down to sub-nanomolar concentrations)
Lower sample volume requirements
Enhanced mechanical stability for repeated use

Improved Specificity Through Surface Modification

The surface of electrospun nanofibers can be easily modified with multiple recognition elements (antibodies, aptamers, molecularly imprinted polymers) to enhance specificity and reduce false positives. This multi-recognition approach has been particularly effective in distinguishing between closely related cancer subtypes.

Point-of-Care Applicability

Unlike many conventional cancer detection systems that require specialized laboratory equipment, electrospun fiber-based biosensors can be designed for point-of-care use. Their flexible, portable nature makes them suitable for use in clinics, remote areas, or even home-based monitoring systems.

Cost-Effectiveness and Scalability

Clearly, the electrospinning process is relatively simple and cost-effective compared to other nanofabrication techniques. The equipment required is less expensive than that needed for techniques like photolithography or electron beam lithography, making electrospun nanofiber technologies more accessible for widespread implementation in cancer diagnostics.

External Validation and Scientific Support

A review published in ACS Applied Materials & Interfaces² confirms that nanofiber-based platforms enhance biosensing sensitivity by closely mimicking biological microenvironments. This external validation supports the growing adoption of electrospun fibers for next-generation cancer diagnostics.

Challenges and Future Directions in Electrospun Biosensors

Despite promising progress, several challenges must be addressed to translate electrospun fiber biosensors from laboratory research to clinical practice:

Scalability: Ensuring reproducibility across production batches
Regulatory compliance: Thorough assessment of biocompatibility and toxicity
Long-term stability: Maintaining membrane sensitivity over extended periods

Current research in electrospinning biomedical applications is focused on:

Smart polymers that respond to specific biomolecular interactions
Real-time readout electronics for continuous monitoring
AI-based data analysis to improve diagnostic accuracy
Biodegradable nanofibrous scaffolds for in vivo cancer sensing
Multi-functional nanofibers that combine detection with therapeutic agent delivery

As these technologies mature, we can expect increasingly sensitive, specific, and user-friendly cancer diagnostic tools based on electrospun nanofibers.

Conclusion: The Future of Cancer Detection Using Electrospun Fibers

Electrospun fibers represent a revolutionary approach to cancer detection and diagnosis, offering unprecedented sensitivity, specificity, and versatility. Their unique structural properties and adaptability make them ideal platforms for developing next-generation cancer biosensors.

As research advances and clinical validation progresses, these electrospun nanofibers will likely play an increasingly important role in early cancer detection efforts, potentially transforming patient outcomes through earlier intervention.

The continued development of electrospinning for cancer detection exemplifies how advanced materials science can address critical healthcare challenges, bridging the gap between laboratory innovation and clinical application. By enabling earlier and more accurate diagnoses—potentially even before symptoms arise—electrospun membranes are poised to become a cornerstone in personalized cancer diagnostics.

If your research team is exploring electrospun nanofibers for biosensor development or cancer diagnostic applications, contact Fluidnatek to learn how our advanced electrospinning technologies can support your research and scale-up efforts. Our precision platforms empower researchers to develop tailored solutions for complex biomedical challenges, from proof-of-concept to commercial scalability.

References

Zhang N, Deng Y, Tai Q, et al. (2012). Electrospun TiO2 Nanofiber-Based Cell Capture Assay for Detecting Circulating Tumor Cells from Colorectal and Gastric Cancer Patients. Advanced Materials. 24(20):2756-2760. https://pubmed.ncbi.nlm.nih.gov/22528884/
Wang X, Wang G, Liu G, et al. (2002). Electrospun Nanofibrous Membranes for Highly Sensitive Optical Sensors. ACS Applied Materials & Interfaces. 8(41):28150-28155. DOI: 10.1021/acsami.6b10269 https://pubs.acs.org/doi/10.1021/nl020216u
Huang, Z-M., Zhang, Y-Z., Kotaki, M., & Ramakrishna, S. (2003). A review on polymer nanofibers by electrospinning and their applications in nanocomposites. Composites Science and Technology, 63(15), 2223–2253. https://doi.org/10.1016/S0266-3538(03)00178-7
Noh, H., Lee, S. H., & Kim, J. (2020). Recent advances in nanofiber-based biosensors for biomedical applications. Biosensors and Bioelectronics, 148, 111800. https://doi.org/10.1016/j.bios.2019.111800
Liu, Y., et al. (2020). Electrospun nanofibers for sensors and wearable electronics: a review. Materials Today, 41, 168–193. https://doi.org/10.1016/j.mattod.2020.08.005
Jiang, Y., et al. (2017). Electrospun nanofiber membranes for efficient cancer cell capture. ACS Applied Materials & Interfaces, 9(12), 11350–11358. https://doi.org/10.1021/acsami.6b15025
ElectrospinTech. (n.d.). Electrospun Membranes for Cancer Cell Detection. Recuperado de: http://electrospintech.com/cancerdetect.html
Wang, L., et al. (2021). Functional electrospun nanofibers for cancer diagnostics. Advanced Functional Materials, 31(20), 2100212. https://doi.org/10.1002/adfm.202100212
Fluidnatek. (2024). Applications of Electrospinning in Biomedical Engineering. https://www.fluidnatek.com/applications

Biomedical

Electrospun Scaffolds for Bone Treatment and Repair: A Breakthrough in Bone Tissue Engineering

Posted on March 31, 2025May 22, 2025 by Vicente Zaragozá

31
Mar

Electrospun scaffolds for bone tissue engineering have emerged as a groundbreaking solution for treating and repairing bone defects. This innovative approach combines advanced materials science with bioengineering principles to create scaffolds that mimic the natural extracellular matrix (ECM) of bone tissue, promoting regeneration and healing

What is Electrospinning and How Does It Work?

Firstly, Electrospinning is a versatile technique that uses electrical forces to produce fine fibers from polymer solutions or melts. The process involves applying a high voltage to a polymer solution made of a polymer and at least one solvent, which is then drawn into ultrafine fibers due to electrical repulsion as it travels towards a grounded collector. This method allows for precise control over fiber diameter, orientation, and composition, making it ideal for creating scaffolds that closely resemble the structure of natural bone tissue.

Applications of Electrospun Fibers in Bone Tissue Engineering

Electrospun scaffolds for bone tissue engineering

For instance, Electrospun scaffolds provide an ideal environment for bone cell growth and differentiation. These scaffolds offer high surface-area-to-volume ratios, porosity, and compositional diversity, which are essential for mimicking the extracellular matrix of natural bone. Recent advancements have addressed challenges such as cell infiltration and 3D tissue formation through innovative techniques like sharp inclined array collectors with point electrodes.

Electrospun bio-nanocomposite scaffolds for bone tissue engineering

Identically, bio-nanocomposite scaffolds combine synthetic or natural polymers with bioactive inorganic materials to enhance mechanical strength and osteoconductivity. For example, incorporating hydroxyapatite nanoparticles into PVA/PVP scaffolds improves cell adhesion and calcium deposition. Additionally, zirconium-reinforced composites have shown increased compressive strength while maintaining cytocompatibility.

Electrospun submicron bioactive glass fibers for bone tissue scaffold

Nonetheless, bioactive glass fibers have gained attention for their ability to bond with bone and stimulate angiogenesis. These fibers, composed of silicon dioxide, calcium oxide, and phosphorus pentoxide, release ions crucial for bone formation. Studies have shown that bioactive glass-PCL composites demonstrate significantly higher alkaline phosphatase activity compared to polymer-only scaffolds, indicating accelerated mineralization.

Electrospun scaffolds for bone tissue engineering have emerged as a groundbreaking solution for treating and repairing bone defects. This innovative approach, particularly, combines advanced materials science with bioengineering principles to create scaffolds that mimic the natural extracellular matrix (ECM) of bone tissue, promoting regeneration and healing.

Advantages of Using Electrospun Fibers to Repair Bone

Certainly, Electrospun nanofibers for bone regeneration offer several advantages over traditional bone repair methods:

Biomimetic structure: Electrospun fibers closely mimic the natural extracellular matrix of bone tissue, providing an ideal environment for cell growth and differentiation.
Tailored properties: The electrospinning process allows for precise control over fiber diameter, orientation, and composition, enabling the creation of scaffolds with optimized mechanical and biological properties.
Enhanced cell adhesion and proliferation: The high surface-area-to-volume ratio of electrospun scaffolds promotes cell attachment and growth.
Controlled drug delivery: Electrospun fibers can be loaded with growth factors, antibiotics, or other therapeutic agents for sustained release, enhancing bone regeneration and reducing infection risks. This approach offers several advantages:
1. Localized delivery: Moreover, the scaffolds can provide targeted release of drugs directly to the bone defect site, maximizing therapeutic efficacy.
2. Sustained release profiles: By carefully selecting polymer-drug combinations and fiber architectures, release kinetics can be tailored to match the healing process, from initial inflammation to long-term bone remodeling.
3. Multi-drug delivery: Different drugs can be incorporated into various fiber populations or layers within the scaffold, allowing for sequential or simultaneous release of multiple therapeutic agents.
4. Protection of sensitive biomolecules: The fibrous structure can shield growth factors and other delicate compounds from degradation, preserving their bioactivity.
5. Reduced systemic side effects: Localized, controlled release minimizes the need for high systemic drug doses, potentially decreasing adverse effects.
6. Infection control: Antibiotics can be incorporated to create an antimicrobial environment, crucial for preventing post-operative infections in bone repair procedures.
7. Synergistic effects: The combination of scaffold architecture and drug delivery can work synergistically to promote cell infiltration, vascularization, and ultimately, bone regeneration
Customizable degradation rates: By selecting appropriate materials and repair processing parameters, the degradation rate of electrospun scaffolds can be tailored to match the rate of new bone formation.

Future Perspectives in Bone Tissue Regeneration

Specifically, the future of electrospun scaffolds for bone tissue engineering looks promising, with several emerging trends:

Multifluid electrospinning: Advanced techniques like coaxial and triaxial systems enable the creation of layered fiber architectures with spatially controlled bioactive agents.
4D dynamic scaffolds: Temperature and pH-responsive fibers that can adapt their pore size post-implantation to accommodate tissue ingrowth are being developed.
AI-driven fabrication: Researchers are employing machine learning algorithms to optimize process parameters and predict scaffold morphology and mechanical performance.
Integration with other technologies: Combining electrospinning with 3D printing, melt electrowriting, electrospraying, and microfluidics is opening new possibilities for creating complex, multifunctional scaffolds.

Overall, the combination of electrospinning and 3D printing or melt electrowriting leverages the strengths of both techniques:

Enhanced structural complexity: 3D printing provides precise control over macrostructure, while electrospinning adds nanofiber layers that mimic the extracellular matrix.
Improved mechanical properties: The integration results in scaffolds with both adequate mechanical strength from 3D-printed structures and high porosity from electrospun fibers.
Hierarchical architectures: This approach allows for the creation of scaffolds with multi-scale features, from nanometer to millimeter ranges.
Fabrication methods:
- Direct electrospinning onto 3D-printed structures
- Alternating layers of 3D-printed and electrospun materials
- Using electrospun nanofibers as a component in 3D printing inks

Conclusion

After all, as research in this field continues to advance, electrospun scaffolds for bone tissue engineering are poised to revolutionize bone treatment and repair, offering personalized solutions for complex bone defects and bridging the gap between laboratory research and clinical application.

In order to learn more about the latest developments in electrospun nanofibers for bone regeneration, check out this comprehensive review from ACS Biomaterials Science & Engineering.

Interested in how electrospinning technology can advance bone tissue engineering? Contact us to explore tailored solutions.

References

Bhardwaj, N., & Kundu, S. C. (2010). Electrospinning: A fascinating fiber fabrication technique. Biotechnology Advances, 28(3), 325-347.
Khajavi, R., Abbasipour, M., & Bahador, A. (2016). Electrospun biodegradable nanofibers scaffolds for bone tissue engineering. Journal of Applied Polymer Science, 133(3), 42883.
Langer, R., & Vacanti, J. P. (1993). Tissue engineering. Science, 260(5110), 920-926.
Li, W. J., Laurencin, C. T., Caterson, E. J., Tuan, R. S., & Ko, F. K. (2002). Electrospun nanofibrous structure: A novel scaffold for tissue engineering. Journal of Biomedical Materials Research, 60(4), 613-621.
Pham, Q. P., Sharma, U., & Mikos, A. G. (2006). Electrospinning of polymeric nanofibers for tissue engineering applications: A review. Tissue Engineering, 12(5), 1197-1211.
Sill, T. J., & von Recum, H. A. (2008). Electrospinning: Applications in drug delivery and tissue engineering. Biomaterials, 29(13), 1989-2006.
Teo, W. E., & Ramakrishna, S. (2006). A review on electrospinning design and nanofibre assemblies. Nanotechnology, 17(14), R89-R106.
Zafar, M., Najeeb, S., Khurshid, Z., Vazirzadeh, M., Zohaib, S., Najeeb, B., & Sefat, F. (2016). Potential of electrospun nanofibers for biomedical and dental applications. Materials, 9(2), 73.

Biomedical

Cell-Seeded Scaffolds: Revolutionizing Biomedical Engineering for Tissue Regeneration

Posted on February 17, 2025May 22, 2025 by Vicente Zaragozá

17
Feb

For decades, researchers in biomedical engineering have strived to unlock the secrets of tissue engineering and tissue regeneration. The ultimate goal: to repair or replace damaged tissues and organs, offering hope to millions suffering from injuries and diseases. One of the most promising approaches in this field involves the creation of cell-seeded scaffolds, structures that mimic the natural environment of cells and guide their growth and development.

The Promise of Cell-Seeded Scaffolds

Imagine a tiny, three-dimensional framework, meticulously designed to support the growth of new tissue. That’s essentially what a cell-seeded scaffold is. These scaffolds provide structural support for cells to attach, proliferate, and differentiate, ultimately forming functional tissue. The beauty of this approach lies in its potential to create personalized, biocompatible implants that seamlessly integrate with the body.

But how are these scaffolds made, and what makes them so effective? The answer lies in a combination of advanced materials science, cell biology, and innovative fabrication techniques.

Electrospinning: A Key Technology for Scaffold Fabrication

Among the various methods used to create tissue affolds, electrospinning stands out as a versatile and powerful technique. This process uses an electrical field to draw charged threads of polymer solutions, creating nanofibers that form a porous, three-dimensional structure. The resulting scaffolds closely resemble the extracellular matrix (ECM), the natural environment surrounding cells in the body.

Advantages of Electrospinning in Tissue Engineering

The advantages of electrospinning for biomedical tissue engineering are numerous:

Tunable architecture: Electrospinning allows for precise control over fiber diameter, porosity, and alignment, enabling the creation of scaffolds tailored to specific tissue types.
Versatile materials: A wide range of polymers, both natural and synthetic, can be electrospun, allowing for the selection of materials with specific properties such as biodegradability, biocompatibility, and mechanical strength.
Scalability: The electrospinning process can be scaled up for mass production, making it a viable option for clinical applications.

Collagen Electrospinning: A Natural Choice

Collagen, the most abundant protein in the human body, is a popular choice for electrospinning scaffolds. Its inherent biocompatibility, biodegradability, and ability to promote cell adhesion make it an ideal material for tissue engineering applications. Collagen electrospinning cell seeding techniques are thus widely studied.

Applications of Collagen Scaffolds

Collagen scaffolds can be used to regenerate and repair different tissues, including:

Skin: Collagen scaffolds can promote wound healing and reduce scarring.
Bone: They can guide the formation of new bone tissue for fracture repair and bone regeneration.
Cartilage: They can support the growth of chondrocytes (cartilage-forming cells) for treating osteoarthritis and other cartilage defects.
Blood vessels: Collagen scaffolds can be used to create vascular grafts for bypass surgery and other cardiovascular applications.

Bio-Electrospinning: Seeding Cells During Scaffold Formation

While traditional methods involve seeding cells onto pre-fabricated scaffolds, a more advanced approach—known as bio-electrospinning cell seeding—integrates cells directly into the electrospinning process. This technique involves suspending cells in the polymer solution and simultaneously electrospinning the polymer while encapsulating the cells within the fibers.

Benefits of Bio-Electrospinning

The benefits of bio-electrospinning are significant:

Enhanced cell viability: Encapsulating cells within fibers protects them from harsh conditions during electrospinning, improving their survival rate.
Uniform cell distribution: Bio-electrospinning ensures homogenous distribution of cells throughout the scaffold, promoting uniform tissue formation.
Improved cell-matrix interactions: Direct encapsulation allows intimate contact between cells and scaffold material, enhancing adhesion, proliferation, and differentiation.

Characterization of the 3DPCL-GelMA Scaffold. (a) A scanning electron microscope (SEM) image showing the cross-section of melt electrospun polycaprolactone (PCL) fibers, arranged in a porous network. The scale bar represents 30 µm. (b) An SEM image depicting a 3D-printed PCL-GelMA (PG) scaffold composed of 50 stacked layers, highlighting its organized microstructure. The scale bar represents 200 µm. (e) A 3DPCL-GelMA scaffold with cells co-cultured, illustrating cell attachment and distribution within the scaffold structure. (f) A 3DPCL-GelMA scaffold after the hydrogel component has been removed, revealing the remaining fibrous architecture. Reference: Kong et al., 2024.

Beyond the Basics: Advanced Electrospinning Techniques

Researchers are continuously developing new electrospinning techniques to further enhance scaffold properties. Some advanced approaches include:

Coaxial Electrospinning

This technique uses two concentric needles to create core-shell fibers. It allows encapsulation of cells or growth factors within the core fiber structure for controlled release or targeted delivery.

Melt Electrospinning Writing (MEW)

MEW offers precise control over molten polymer deposition. This enables highly defined 3D scaffolds with controlled architecture and mechanical properties.

Combining Electrospinning with Electrospraying

Combining electrospinning with electrospraying produces 3D scaffolds that incorporate stem cells directly into their structure. This technique enhances cell integration within scaffolds.

Hybrid 3D Printing and Electrospinning

This method combines 3D printing with electrospinning to fabricate complex tissue structures like vascular patches or organ-like constructs.

These advanced techniques offer unprecedented control over scaffold properties and cell behavior, paving the way for more effective therapies in biomedical engineering tissue regeneration.

Illustration of histological cross-sections of scaffolds seeded with cells after different cultivation periods: (A) After 1 day, showing initial cell attachment and distribution (magnification: ×200). (B) After 15 days, revealing enhanced cell proliferation and scaffold integration (magnification: ×100). Scale bars: 50 µm. [Braghirolli et al., 2015].

Challenges and Future Directions

While cell-seeded scaffolds hold immense promise for tissue engineering, several challenges remain:

Scalability: Scaling up production while maintaining quality is critical for clinical translation.
Vascularization: Engineering functional blood vessels within scaffolds is essential for nutrient delivery.
Immune response: Minimizing immune reactions is vital for long-term success.

Future Research Goals

Future research efforts will focus on:

Developing biomaterials with improved biocompatibility.
Incorporating bioactive molecules like growth factors into scaffolds.
Designing more sophisticated scaffold architectures that mimic native tissues.
Promoting vascularization strategies while minimizing immune responses.

Conclusion

Cell-seeded scaffolds represent a groundbreaking advancement in biomedical engineering. By combining innovative technologies like collagen electrospinning cell seeding with advanced fabrication techniques such as bio-electrospinning or coaxial electrospinning, researchers are pushing the boundaries of what’s possible in regenerative medicine. With continued innovation, these technologies could revolutionize treatments for injuries and diseases—bringing us closer to a future where personalized tissue implants are readily available.

References:

Author: Wee-Eong TEO

Ang H Y, Irvine S A, Avrahami R, Sarig U, Bronshtein T, Zussman E, Boey F Y C, Machluf M, Venkatraman. Characterization of a bioactive fiber scaffold with entrapped HUVECs in coaxial electrospun core-shell fiber. Biomatter 2014; 4: e28238. View
Braghirolli D I, Zamboni F, Acasigua G A X, Pranke P. Association of electrospinning with electrospraying: a strategy to produce 3D scaffolds with incorporated stem cells for use in tissue engineering. International Journal of Nanomedicine 2015; 10: 5159.
Erben J, Jirkovec R, Kalous T, Klicova M, Chvojka J. The Combination of Hydrogels with 3D Fibrous Scaffolds Based on Electrospinning and Meltblown Technology. Bioengineering. 2022; 9(11):660.
Kong X, Zhu D, Hu Y, Liu C, Zhang Y, Wu Y, Tan J, Luo Y, Chen J, Xu T, Zhu L. Melt electrowriting (MEW)-PCL composite Three-Dimensional exosome hydrogel scaffold for wound healing. Materials & Design 2024; 238: 112717.
Lee H, Kim G H. Enhanced cellular activities of polycaprolactone/alginate-based cell-laden hierarchical scaffolds for hard tissue engineering applications. Journal of Colloid and Interface Science 2014; 430: 315.

Biomedical

Visionary solutions: electrospun implants giving new hope to nerve recovery

Posted on December 19, 2024May 22, 2025 by Vicente Zaragozá

19
Dec

The Role of Biomaterials in Treating Peripheral Nerve Injury

Peripheral nerve injury (PNI) remains a significant medical challenge due to its slow recovery process and complex clinical outcomes. When a nerve is damaged, prolonged denervation can lead to muscle atrophy and reduced Schwann cell activity, both critical for axonal regeneration. In response, innovative approaches such as biomaterial-based implants have emerged as promising solutions to accelerate nerve recovery.

While drugs like ibuprofen have shown potential in promoting nerve regeneration through anti-inflammatory properties, systemic administration often causes unwanted side effects. To overcome this, electrospinning in the biomedical field has gained traction as a method for delivering drugs directly to the injury site via polymer-based scaffolds. Recently, the University College London School of Pharmacy published a study in which the team developed ibuprofen-loaded electrospun materials suitable for surgical implantation in peripheral nerve injuries using our Fluidnatek LE-50 G2 equipment.

What is Electrospinning and Why is it Ideal for Nerve Recovery?

Electrospinning is a versatile technique that transforms polymer solutions into fine, nano- to micro-scale fibers by applying a high-voltage electric field. These fibers are collected into mats that mimic the extracellular matrix of tissues, making them ideal candidates for biomedical applications, especially in nerve repair.

The advantages of electrospun materials include:

Customizability: Physical properties like mechanical strength and drug release rates can be tuned.
Biocompatibility: Synthetic polymers such as polycaprolactone (PCL) and polylactic acid (PLA) are widely used due to their compatibility with biological systems.
Sustained Drug Release: Electrospun fibers can encapsulate drugs like ibuprofen, ensuring controlled and prolonged release at the target site.

For peripheral nerve injury, electrospun wraps or implants loaded with therapeutic agents significantly enhance the healing process by delivering localized treatment, minimizing side effects.

Electrospinning and Ibuprofen Delivery for Nerve Recovery

Recent advancements have demonstrated the successful development of ibuprofen-loaded electrospun biomaterials for peripheral nerve injury. Ibuprofen, a widely used non-steroidal anti-inflammatory drug (NSAID), is known to improve nerve regeneration by inhibiting inflammatory responses and promoting neurite growth.

In a cutting-edge study, researchers optimized the use of electrospun nerve wraps fabricated from PCL, PLA, and their copolymers. The following findings underscore the potential of these polymer-based implants:

Optimized Fiber Properties: Electrospinning parameters were tuned to produce smooth, defect-free fibers with varying diameters. The incorporation of ibuprofen into these fibers allowed for a controlled, sustained release over 21 days.
Surgical Handling: User evaluations highlighted the importance of mechanical properties, with PLA/PCL (70/30) blends demonstrating superior flexibility and strength, making them ideal for nerve-wrapping applications.
In Vivo Performance: In animal models, ibuprofen-loaded electrospun materials accelerated nerve regeneration. Axon counts in treated nerves were significantly higher compared to controls, confirming the therapeutic effect of localized ibuprofen delivery.

Photographs showing stages of electrospun material implantation procedure in a rat sciatic nerve crush model.

Polymer Selection in Electrospinning for Biomedical Implants

The success of electrospun biomaterials depends heavily on the choice of polymers. For peripheral nerve injury, polymers must exhibit biocompatibility, biodegradability, and mechanical stability. The following polymers are commonly employed:

Polylactic Acid (PLA): Known for its slow degradation rate, PLA provides a robust structure but can be brittle.
Polycaprolactone (PCL): Offers excellent flexibility and strength, ideal for implants requiring pliability.
PLA/PCL Copolymers: Combining the strengths of PLA and PCL, these copolymers achieve the desired balance of mechanical stability and handling ease.

In the case of ibuprofen-loaded electrospun implants, PLA/PCL (70/30) was identified as the most suitable formulation due to its superior surgical handling and sustained drug release profile.

Summary of formulation properties. Scanning electron micrographs (A) reveal cylindrical fibres with no visible defects. A histogram of fibre diameters (B) shows unimodal distribution for all tested formulations. Cumulative ibuprofen release data (C) present an initial burst release followed by a period of sustained release over 21 days (Each formulation was tested in triplicate, and the results are presented as mean ± SEM (n = 3)).

The Future of Electrospun Biomaterials in Nerve Repair

As research in the biomedical field advances, electrospinning continues to demonstrate immense potential for improving outcomes in nerve injuries. Key areas of future development include:

Scalable Manufacturing: Ensuring that electrospun materials can be mass-produced for clinical use.
Advanced Drug Loading: Incorporating multiple therapeutic agents for synergistic effects on nerve regeneration.
Clinical Trials: Translating promising in vivo results into human applications to validate the efficacy and safety of electrospun biomaterials.

Conclusion

The use of electrospinning in the biomedical field has revolutionized the development of drug-loaded implants for peripheral nerve injury. By leveraging polymers such as PLA and PCL, researchers have created biomaterials capable of delivering sustained, localized treatment, accelerating nerve regeneration and functional recovery.

Ibuprofen-loaded electrospun fibers represent a significant advancement in nerve recovery strategies, offering a targeted, effective, and minimally invasive solution. As the field continues to evolve, these innovative biomaterials hold the promise of transforming peripheral nerve injury treatment and enhancing patient outcomes.

References

Karolina Dziemidowicz, Simon C. Kellaway, Owein Guillemot-Legris, Omar Matar, Rita Pereira Trindade, Victoria H. Roberton, Melissa L.D. Rayner, Gareth R. Williams, James B. Phillips,

Development of ibuprofen-loaded electrospun materials suitable for surgical implantation in peripheral nerve injury,

Biomaterials Advances,

Volume 154, 2023, 213623,

ISSN 2772-9508,

*All images in the article are the property of the authors.

Biomedical

DRUG-LOADED ELECTROSPUN YARNS OF APPLICATION AS ANTIMICROBIAL SURGICAL SUTURES

Posted on June 3, 2024May 22, 2025 by Vicente Zaragozá

03
Jun

Electrospinning for Drug-Loaded Surgical Sutures

The objective of the research work presented in this application note is to develop a suture thread composed of fibers obtained by electrospinning (surgical suture yarns made of electrospun fibers) and interwoven using an electrospun fiber-yarn collector. Ciprofloxacin has been added as an antimicrobial agent to prevent surgical site infections.

In other words, electrospinning technology is positioned as a high-potential alternative for the development of surgical sutures constructed from nanofibers (electrospun nanofibers in this case).

The polymer chosen for the yarn is PHBV, with three variants containing different 3HV unit contents tested.

A complete characterization of the different suture yarns (i.e., the different electrospun yarns obtained) has been carried out, evaluating both their mechanical properties and antimicrobial efficacy. The results show promising mechanical properties and a high antimicrobial effect.

Antimicrobial Properties of Ciprofloxacin-Loaded Electrospun Yarns

Sutures are a routine surgical procedure used to close wounds and join tissues. Due to their intrinsic characteristics, these interventions are susceptible to the emergence of pathogens, leading to what are known as surgical site infections (SSIs).

SSIs cause a large number of medical complications, as well as increased morbidity, mortality, and associated healthcare costs. Over time, a variety of suture threads have been developed based on the characteristics of the tissue to be sutured.

However, despite the significant drawbacks of SSIs, little progress has been made in improving the therapeutic effect of suture threads to prevent these infections.

Generally, the incorporation of antimicrobial substances has been carried out using techniques such as melt spinning, dip coating, or soaking, among others. While these techniques have been shown to be effective to some extent, none of them properly encapsulate the substance of interest. As a result, the release profile and stability over time are not adequately controlled.

This is where the electrospinning technique can provide additional value in the development of drug-loaded electrospun yarns.

Electrospinning for Drug Delivery: A Novel Approach to Encapsulating Bioactive Compounds

In this sense, the technique that has proven to be able to incorporate drugs effectively is electrospinning. Electrospinning allows obtaining nanostructures and microstructures that can incorporate drugs into their polymeric matrix in a single step, thus substantially improving their release process. In addition, another great advantage of using electrospinning for this application is that it is not necessary to use high temperatures to obtain nanofibers, which makes it possible to encapsulate compounds such as proteins, growth factors, peptides, DNA or other substances that would not be possible to encapsulate with other techniques such as melt spinning.

In this scientific contribution, members of Bioinicia‘s R&D department develop a suture thread composed of nanofibers obtained by electrospinning and interwoven by means of a device called electrospun fiber-yarn collection module, an accessory developed by Fluidnatek (Bioinicia Fluidnatek being a subsidiary of the Bioinicia Group), to which ciprofloxacin has been added as an antimicrobial agent.

Mechanical Performance of Electrospun Suture Yarns

There are different biopolymers used in biomedical applications. From PLLA, considered the gold standard, to PEG, PLGA, PDS, PLA or PHA. All of them are polymers that can be processed by electrospinning. Within the PHAs family, which is a biodegradable and highly biocompatible polymer, much research has been done on PHB and, within this, on its copolymer PHBV (poly(3-hydroxybutyrate-co-3-hydroxyvalerate). PHB has high crystallinity and macromolecular organization, resulting in a rigid and brittle material that lacks mechanical strength. On the other hand, PHBV co-polyester shows improved thermal and mechanical properties, which vary depending on the content of 3HV units present in the polyester.

In this work, ciprofloxacin hydrochloride (CPX) has been used as an antimicrobial substance to encapsulate electrospun nanofibers. CPX is an antibiotic belonging to the fluoroquinolone family, with known efficacy against Gram-positive and Gram-negative bacteria.

In this study, 3 types of suture threads based on PHBV polymer with different contents of 3HV units, namely 2%, 10% and 20% molar, have been developed. In all cases, PHBV has been dissolved at 8% wt in TFE (2,2,2-trifluoroethanol). CPX was added at 20% wt in the ratio to the amount of polymer.

Electrospinning for Suture Yarn Production: Process, Equipment, and Material Analysis

The throughput production pilot plant can also implement the electrospun fiber-yarn collector module in its configuration. The solution, contained in a syringe, is pushed by a pump until it emerges from the needle tip.

The high electric field present between the needle tip and the collector elongates the solution, forming a jet due to the electric field’s action. This increases the contact surface between the solution and the medium, causing the evaporation of the solvent and the creation of nanofibers. This is the fundamental process behind the electrospinning technique.

To generate the suture yarns, an accessory called the fiber yarn collector module, developed by Fluidnatek, has been used. This accessory consists of a rotating funnel over which the nanofibers generated by electrospinning are directed.

As the nanofibers approach the funnel, they intertwine following the direction of rotation, eventually forming a yarn that is continuously collected by a rotating reel.

To ensure consistency and reproducibility in the manufacturing of the suture yarns, an Environmental Control Unit (ECU) has been used. The ECU sets specific temperature and relative humidity values—30°C and 30% RH, respectively.

The Environmental Control Unit has also been developed by Fluidnatek, specifically designed for its electrospinning equipment and the unique evaporative process of electrospinning (and electrospraying).

This version makes the information easier to follow while keeping technical details intact.

The mechanical and antimicrobial properties of the different drug-loaded yarns made of electrospun fibers obtained have been evaluated by SEM (scanning electron microscopy) imaging, Fourier transform infrared spectroscopy, wide-angle X-ray scattering, differential scanning calorimetry and in vitro drug release monitoring.

Results and conclusion

The 3 suture yarns generated by electrospinning from PHBV with different concentrations of 3HV units and loaded with CPX show a cylindrical morphology with a total diameter between 300 and 500 μm, composed in turn of individual fibers obtained by the electrospinning process, each of these fibers in turn with an average diameter between 1 and 3 μm. CPX appears in an amorphous state within the yarns and the crystallinity of the polymer decreases as the content of 3HV units increases, which in turn is related to the drug release profile. The presence of CPX in the threads has shown high antibacterial activity for two typical pathogens, one Gram-positive and the other Gram-negative, so these suture threads could be suitable in surgical procedures to prevent SSIs.

Despite the promising mechanical properties and the high antimicrobial effect, the elasticity of the suture yarns generated so far does not reach that of traditional suture yarns, so this parameter should be improved in the future so that this type of yarn could be an alternative to those currently used. But what is clear is that electrospinning is positioned as a serious alternative to produce continuous fiber yarns, and in the specific case that applies to this application note to produce drug-loaded electrospun fiber yarns for medical purposes.

References

Pharmaceutics 2024, 16(2), 220

https://doi.org/10.3390/pharmaceutics16020220