In situ 3D-patterning of electrospun fibers using two-layer composite materials

Area of Science:

• Materials Science
• Nanotechnology
• Biomedical Engineering

Background:

• Polymeric electrospun nanofibers are crucial for applications like filtration, sensing, drug delivery, and tissue engineering.
• Integrating or patterning these nanofibers into devices is often required but challenging.

Purpose of the Study:

• To develop a versatile in situ strategy for three-dimensional (3D) electrospun fiber patterning.
• To demonstrate the effectiveness and adaptability of this patterning method across various materials and dimensions.
• To explore novel applications of patterned nanofibers, such as in dissolving microneedles.

Main Methods:

• Utilizing collectors with an insulative surface layer and conductive recessed patterns for in situ fiber deposition.
• Fabricating two-layer collectors with pattern dimensions as small as 100 micrometers using standard laboratory equipment.
• Employing finite element method (FEM) simulation and experimental validation to confirm patterning accuracy.
• Integrating patterned electrospun fibers into dissolving microneedle devices.

Main Results:

• The developed strategy effectively patterns electrospun nanofibers in 3D with high versatility.
• The collector fabrication is straightforward and achievable with existing laboratory resources.
• FEM simulations and experimental results confirmed the strategy's efficacy for diverse fiber materials and pattern sizes.
• Successful incorporation of patterned nanofibers into dissolving microneedles was achieved for the first time.

Conclusions:

• A novel and adaptable in situ electrospun fiber patterning technique has been established.
• This method provides a framework for precise control over nanofiber placement in 3D structures.
• The demonstrated application in dissolving microneedles highlights the potential for new biomedical and other technological advancements.