$$\rightleftharpoonup{xx}$$
$$\longleftharp{xx}$$,
$$\longrightharp{xx}$$,
The creation of different fiber sizes was achieved using a combination of different solvents, PCL concentrations, and electrospinning parameters. The type of polymer, its molecular weight, and the solvent strongly affect the viscosity and charge properties of the resulting solution and therefore bear a strong influence on the electrospinning properties31. The voltages displayed in this method are subject to change based upon the conditions in which the electrospinning is conducted. Temperature and humidity affect the behavior of the electrospinning process32. Therefore, the reader is advised to be prepared to change the voltage to counter any hindrances and achieve a stable Taylor cone. It is recommended to house the electrospinner within an environmental control enclosure to reduce batch-to-batch variability in the electrospinning process.
Achieving the different morphologies presented in this method is possible due to the capabilities of the IME electrospinning device. A variable speed mandrel is essential for controlling fiber alignment. Mandrel rotation at a low rpm (<250 rpm) yields randomly oriented fibers due to the behavior of the polymer jet. When the charged polymer solution is emitted from the needle, the internal charges and aerodynamic forces induce a chaotic whipping effect that is utilized to lay down a chaotic arrangement of fibers on the mandrel33,34. This whipping effect can be overcome by increasing the mandrel rotation speed above 1,800 rpm. Fibers deposited on such a high rpm mandrel exhibit an aligned structure because the surface speed is enough to effectively counter any transverse movement exhibited by the whipping fiber. It is important to note that when high mandrel speeds are used, it is likely to disrupt the surrounding air, which can have an adverse effect on the production of a stable Taylor cone.
Highly porous cryogenic scaffolds are produced by filling the mandrel with dry ice at -78.5 °C. This reduces the temperature of the mandrel and promotes condensation and freezing of water droplets on the surface. The crystals formed exhibit peaks that emerge from the mandrel surface and the fibers are deposited throughout the peaks. Once the ice crystals are sublimated out, a porous structure of fibers remains on the mandrel35,36. The weight and fragility of the crystals limit the ability to create porous aligned fibers, as too high mandrel speeds (>250 rpm) result in the crystals and fibers detaching from the mandrel due to excessive centripetal and aerodynamic forces. It is possible to face difficulties with this method due to the fragility of the structures formed. Care must be taken when handling the mandrel and also when handling the scaffolds afterwards, because the structures are prone to being flattened when squeezed and folded when removing from liquids. There is also the possibility that solutions that electrospin successfully without the cryogenic mandrel can be fatally disrupted by the temperature change and the crystal structures. When cryo-spinning, the amount of ice formed on the mandrel surface is highly dependent on the humidity, producing variability in the final result. It is therefore highly recommended to contain the electrospinning process within an environmental control enclosure.
To assess cellular performance on these scaffolds, it is necessary to sterilize the material beforehand. There are many options available for sterilizing polymers, including chemical methods, radiation methods, and heat-based methods37,38. It is important to assess the effectiveness of each method and the suitability for both the use of the material and for the material itself. This protocol uses sterilization in 70% ethanol before lyophilizing, plasma treating, and submerging in 1% Anti-Anti solution. The use of ethanol allows proteins and microorganisms to be denatured and dehydrated while not disrupting the PCL material37. The use of stronger solvents may result in the dissolution of the PCL. Plasma coating was incorporated in this method primarily to increase the hydrophilicity of PCL, which is notoriously hydrophobic, and improve cell attachment39,40. Conveniently, this also works as a secondary sterilization step, but care must be taken to keep the scaffolds in a sterile environment pre and post plasma treatment. This method has proven suitable for in vitro studies with antibiotic treated media. However, for in vivo applications, more robust options such as ethylene oxide (EtO) and gamma exposure must be considered. Once sterilization has been performed, cells can be seeded onto the scaffold and standard cell culture techniques can be applied to form 3D cell cultures in vitro.
It is important to note that the stiffness values should be attributed to the different microstructures formed within the scaffolds. The bulk material (PCL) remains constant between scaffolds. Therefore, the bulk material stiffness does not change between groups. The cryogenic scaffolds display a much lower stiffness than the other groups due to the reduced connectivity within the fiber matrix, which can be seen in Table 1. The reduced connectivity is thought to induce a more bending-dominant deformation as opposed to stretching-dominant deformation within the fibrous structure41. Interestingly, the scaffold stiffness is not highly dependent on fiber size in the random and cryogenic groups. However, the longitudinal stiffness of the aligned fibers shows a significantly higher dependence on fiber size with the Youngs' Modulus at 0-2% strain being 27.94 ± 8.63 MPa for small fibers and 46.94 ± 3.48 MPa for large fibers. Due to the stretching nature of the tensile test, this implies a higher bulk PCL density within the longitudinal cross section. It is necessary to reiterate that the mechanical data presented here is a macroscale mechanical snapshot of the fibrous architectures. Further micromechanical characterization would be beneficial to fully understand the mechanical influences on the cell scale.
Both random and aligned architectures were included in this method to provide a comparison between isotropic and anisotropic morphologies. The extent of fiber alignment can be observed in the SEM images in Figure 2 and the fiber analyses presented in Figure 2 and Figure 3. Anisotropic properties are observed throughout many of the tissues in the body. In particular, this is commonly observed in aligned cellular structures such as those found in muscle and nerve tissues. Aligned polymeric fiber structures offer the capability of recapitulating these aligned structures in vitro42,43. As described before, cell function is sensitive to morphological and mechanical changes, so further functional analysis should be conducted on scaffold-bound cells to determine the biological influence of each scaffold type.
Compared to other existing scaffold fabrication techniques, this method provides a simple way to produce microscale scaffold structures with comparatively high control over the mechanical properties and morphology. Alternative PCL scaffold fabrication such as phase separation, salt leaching, and gas foaming allow for morphological control in terms of void space and pore size. However, the pore and structural geometry remains largely the same44,45,46,47. Therefore, qualities such as the level of isotropy cannot be altered as easily in comparison to electrospinning. Hydrogel materials, popular for scaffold production, provide the means to alter the stiffness of the polymer substrate through alteration of the level of cross-linked polymer chains48. It is also possible to 3D print via a variety of methods, providing excellent control over morphology49. However, achieving electrospinning scale resolution in biocompatible hydrogel materials remains a challenge to be practically implemented50,51. Electrospun scaffolds have featured commonly in tissue engineering research throughout the last decade, and the introduction of new materials and applications with different cell types is always being explored. While new materials are constantly under development for the purpose of electrospinning scaffolds, opportunities for further biological characterization of existing electrospinning materials and methods remain. The method described is proposed as a method for facilitating in vitro biological study, as it is directly applicable to basic cell culture techniques.