Cell Guiding Multicomponent Nanoyarn Tendon Scaffolds with Tunable Morphology and Flexibility.

Nanofibrous scaffolds are widely investigated for tendon tissue engineering due to their porous structure, high flexibility, and the ability to guide cells in a preferred direction. Previous research has shown that providing a microenvironment similar to in vivo settings improves tissue regeneration. Therefore, in this work, ingenious multicomponent nanoyarn scaffolds that mimic the fibrillar and tubular structures of tendons are developed for the first time through electrospinning and bundling nanoyarns followed by electrospinning of a nanofibrous shell around the bundle. Multicomponent nanoyarn scaffolds out of poly(ε-caprolactone) with varying porosity, density, and diameter were successfully produced by coelectrospinning with water-soluble poly(2-ethyl-2-oxazoline) as a sacrificial component. The diameter and fiber orientation of the nanoyarns were successfully tuned based on parameter-morphology models obtained by the design of experiments. Cyclic bending tests were performed, indicating that the flexibility of the multicomponent nanoyarn scaffolds depends on the morphology and can be tuned through controlling the number of nanoyarns in the bundle and the porosity. Indirect and direct cell culture tests using mouse and equine tendon cells revealed excellent cytocompatibility of the nanofibrous products and demonstrated the potential of the nanoyarns to guide the growing cells along the nanofiber direction, which is crucial for tendon tissue engineering.

Microscale and Macroscale Deformation Behavior of Electrospun Polymeric Nanofiber Membranes Using In Situ SEM during Mechanical Testing.

Electrospun nanofiber membranes show high potential in various application fields (e.g., filtration, catalysis, and sensing). Nevertheless, knowledge of the mechanical behavior, and more specifically, the deformation of nanofiber membranes is still limited today which can complicate the appliance of nanofiber membranes in applications where they are mechanically loaded. In this paper, we, therefore, analyzed the mechanical behavior of polymeric nanofiber membranes with different fiber orientations (random and aligned) extensively. Polyamide 6 was used as a representative reference polymer for proof-of-concept. Mechanical tests show that all membranes have a coherent deformation behavior at the macroscale up to the point of fracture. Large variations in stiffness, ultimate strength, and ultimate strain were observed between membranes with different fiber orientations (Random: E-mod: 370 ± 34 MP; UTS: 38.5 ± 6.0 MPa; εmax: 30.0 ± 2.8%; Parallel aligned: E-mod: 753 ± 11 MPa; UTS: 55.4 ± 0.8 MPa; εmax: 12.0 ± 0.1%; Perpendicular aligned: E-mod: 24.1 ± 3.7 MPa; UTS:/; εmax: >40%). This shows the versatility and tunability of the mechanical behavior of these nanofiber membranes. At the microscale, the fibrous structure results in deformation mechanisms that resist failure formation and progression when the membrane is mechanically loaded. This results in a high fracture resistance, even for pre-damaged membranes. Realignment of the fibers along the loading direction causes crack tip blunting, locally reinforcing the membrane.

Continuous Fiber-Reinforced Aramid/PETG 3D-Printed Composites with High Fiber Loading through Fused Filament Fabrication.

Recent development in the field of additive manufacturing, also known as three-dimensional (3D) printing, has allowed for the incorporation of continuous fiber reinforcement into 3D-printed polymer parts. These fiber reinforcements allow for the improvement of the mechanical properties, but compared to traditionally produced composite materials, the fiber volume fraction often remains low. This study aims to evaluate the in-nozzle impregnation of continuous aramid fiber reinforcement with glycol-modified polyethylene terephthalate (PETG) using a modified, low-cost, tabletop 3D printer. We analyze how dimensional printing parameters such as layer height and line width affect the fiber volume fraction and fiber dispersion in printed composites. By varying these parameters, unidirectional specimens are printed that have an inner structure going from an array-like to a continuous layered-like structure with fiber loading between 20 and 45 vol%. The inner structure was analyzed by optical microscopy and Computed Tomography (µCT), achieving new insights into the structural composition of printed composites. The printed composites show good fiber alignment and the tensile modulus in the fiber direction increased from 2.2 GPa (non-reinforced) to 33 GPa (45 vol%), while the flexural modulus in the fiber direction increased from 1.6 GPa (non-reinforced) to 27 GPa (45 vol%). The continuous 3D reinforced specimens have quality and properties in the range of traditional composite materials produced by hand lay-up techniques, far exceeding the performance of typical bulk 3D-printed polymers. Hence, this technique has potential for the low-cost additive manufacturing of small, intricate parts with substantial mechanical performance, or parts of which only a small number is needed.

Computational prediction of the molecular configuration of three-dimensional network polymers.

The three-dimensional arrangement of natural and synthetic network materials determines their application range. Control over the real-time incorporation of each building block and functional group is desired to regulate the macroscopic properties of the material from the molecular level onwards. Here we report an approach combining kinetic Monte Carlo and molecular dynamics simulations that chemically and physically predicts the interactions between building blocks in time and in space for the entire formation process of three-dimensional networks. This framework takes into account variations in inter- and intramolecular chemical reactivity, diffusivity, segmental compositions, branch/network point locations and defects. From the kinetic and three-dimensional structural information gathered, we construct structure-property relationships based on molecular descriptors such as pore size or dangling chain distribution and differentiate ideal from non-ideal structural elements. We validate such relationships by synthesizing organosilica, epoxy-amine and Diels-Alder networks with tailored properties and functions, further demonstrating the broad applicability of the platform.

In-Situ Observations of Microscale Ductility in a Quasi-Brittle Bulk Scale Epoxy.

Fiber reinforced composite materials are typically comprised of two phases, i.e., the reinforcing fibers and a surrounding matrix. At a high volume fraction of reinforcing fibers, the matrix is confined to a microscale region in between the fibers (1-200 µm). Although these regions are interconnected, their behavior is likely dominated by their micro-scale. Nevertheless, the characterization of the matrix material (without reinforcing fibers) is usually performed on macroscopic bulk specimens and little is known about the micro-mechanical behavior of polymer matrix materials. Here, we show that the microscale behavior of an epoxy resin typically used in composite production is clearly different from its macroscale behavior. Microscale polymer specimens were produced by drawing microfibers from vitrifying epoxy resin. After curing, tensile tests were performed on a large set of pure epoxy microfiber specimens with diameters ranging from 30 to 400 µm. An extreme ductility was observed for microscale epoxy specimens, while bulk scale epoxy specimens showed brittle behavior. The microsized epoxy specimens had a plastic deformation behavior resulting in a substantially higher ultimate tensile strength (up to 380 MPa) and strain at break (up to 130 %) compared to their bulk counterpart (68 MPa and 8%). Polarized light microscopy confirmed a rearrangement of the internal epoxy network structure during loading, resulting in the plastic deformation of the microscale epoxy. This was further accompanied by in-situ electron microscopy to further determine the deformation behavior of the micro-specimens during tensile loading and make accurate strain measurements using video-extensometry. This work thus provides novel insights on the epoxy material behavior at the confined microscale as present in fiber reinforced composite materials.

The Transferability and Design of Commercial Printer Settings in PLA/PBAT Fused Filament Fabrication.

In many fused filament fabrication (FFF) processes, commercial printers are used, but rarely are printer settings transferred from one commercial printer to the other to give similar final tensile part performance. Here, we report such translation going from the Felix 3.0 to Prusa i3 MK3 printer by adjusting the flow rate and overlap of strands, utilizing an in-house developed blend of polylactic acid (PLA) and poly(butylene adipate-co-terephthalate) (PBAT). We perform a sensitivity analysis for the Prusa printer, covering variations in nozzle temperature, nozzle diameter, layer thickness, and printing speed (Tnozzle, dnozzle, LT, and vprint), aiming at minimizing anisotropy and improving interlayer bonding. Higher mass, larger width, and thickness are obtained with larger dnozzle, lower vprint, higher LT, and higher Tnozzle. A higher vprint results in less tensile strain at break, but it remains at a high strain value for samples printed with dnozzle equal to 0.5 mm. vprint has no significant effect on the tensile modulus and tensile and impact strength of the samples. If LT is fixed, an increased dnozzle is beneficial for the tensile strength, ductility, and impact strength of the printed sample due to better bonding from a wider raster structure, while an increased LT leads to deterioration of mechanical properties. If the ratio dnozzle/LT is greater than 2, a good tensile performance is obtained. An improved Tnozzle leads to a sufficient flow of material, contributing to the performance of the printed device. The considerations brought forward result in a deeper understanding of the FFF process and offer guidance about parameter selection. The optimal dnozzle/vprint/LT/Tnozzle combination is 0.5 mm/120 mm s-1/0.15 mm/230 °C.

Improving Mechanical Properties for Extrusion-Based Additive Manufacturing of Poly(Lactic Acid) by Annealing and Blending with Poly(3-Hydroxybutyrate).

Based on differential scanning calorimetry (DSC), X-ray diffraction (XRD) analysis, polarizing microscope (POM), and scanning electron microscopy (SEM) analysis, strategies to close the gap on applying conventional processing optimizations for the field of 3D printing and to specifically increase the mechanical performance of extrusion-based additive manufacturing of poly(lactic acid) (PLA) filaments by annealing and/or blending with poly(3-hydroxybutyrate) (PHB) were reported. For filament printing at 210 °C, the PLA crystallinity increased significantly upon annealing. Specifically, for 2 h of annealing at 100 °C, the fracture surface became sufficiently coarse such that the PLA notched impact strength increased significantly (15 kJ m-2). The Vicat softening temperature (VST) increased to 160 °C, starting from an annealing time of 0.5 h. Similar increases in VST were obtained by blending with PHB (20 wt.%) at a lower printing temperature of 190 °C due to crystallization control. For the blend, the strain at break increased due to the presence of a second phase, with annealing only relevant for enhancing the modulus.

Nanostructured Hydrogels by Blend Electrospinning of Polycaprolactone/Gelatin Nanofibers.

Nanofibrous membranes based on polycaprolactone (PCL) have a large potential for use in biomedical applications but are limited by the hydrophobicity of PCL. Blend electrospinning of PCL with other biomedical suited materials, such as gelatin (Gt) allows for the design of better and new materials. This study investigates the possibility of blend electrospinning PCL/Gt nanofibrous membranes which can be used to design a range of novel materials better suited for biomedical applications. The electrospinnability and stability of PCL/Gt blend nanofibers from a non-toxic acid solvent system are investigated. The solvent system developed in this work allows good electrospinnable emulsions for the whole PCL/Gt composition range. Uniform bead-free nanofibers can easily be produced, and the resulting fiber diameter can be tuned by altering the total polymer concentration. Addition of small amounts of water stabilizes the electrospinning emulsions, allowing the electrospinning of large and homogeneous nanofibrous structures over a prolonged period. The resulting blend nanofibrous membranes are analyzed for their composition, morphology, and homogeneity. Cold-gelling experiments on these novel membranes show the possibility of obtaining water-stable PCL/Gt nanofibrous membranes, as well as nanostructured hydrogels reinforced with nanofibers. Both material classes provide a high potential for designing new material applications.

Damage-Resistant Composites Using Electrospun Nanofibers: A Multiscale Analysis of the Toughening Mechanisms.

Today, fiber-reinforced polymer composites are a standard material in applications where a high stiffness and strength are required at minimal weight, such as aerospace structures, ultralight vehicles, or even flywheels for highly efficient power storage systems. Although fiber-reinforced polymer composites show many advantages compared to other materials, delamination between reinforcing plies remains a major problem limiting further breakthrough. Traditional solutions that have been proposed to toughen the interlaminar region between reinforcing plies have already reached their limit or have important disadvantages such as a high cost or the need for adapted production processes. Recently, electrospun nanofibers have been suggested as a more viable interlaminar toughening method. Although the expected benefits are numerous, the research on composite laminates enhanced with electrospun nanofibrous veils is still very limited. The work that has been done so far is almost exclusively focused on interlaminar fracture toughness tests with different kinds of nanofibers, where typically a trial and error approach has been used. A thorough understanding of the micromechanical fracture mechanisms and the parameters to obtain toughened composites has not been reported as of yet, but it is crucial to advance the research and design highly damage-resistant composites. This article provides such insight by analyzing the nanofiber toughening effect on three different levels for several nanofiber types. Only by combining the results from different levels, a thorough understanding can be obtained. These levels correspond to the hierarchical nature of a composite: the laminate, the interlaminar region, and the matrix resin. It is found that each level corresponds to certain mechanisms that result in a toughening effect. The bridging of microcracks by electrospun nanofibers is the main toughening mechanism resulting in damage resistance. Nevertheless, the way in which the nanofiber bridging mechanism expresses itself is different for each scale and dependent on parameters linked to a certain scale. The multiscale analysis of the toughening mechanisms reported in this paper is therefore crucial for understanding the behavior of nanofiber toughened composites, and as such allows for designing novel, damage-resistant, nanofiber-toughened materials.