Electrospinning: from basic research to commercialization

279 Pages·2018·18.487 MB·English

by  Ghosal, Kajal editor, Kny, Erich, Thomas, Sabu editor

Electrospinning
From Basic Research to Commercialization
Soft Matter Series
Series editors:
Hans-Jürgen Butt, Max Planck Institute for Polymer Research, Germany
Ian W. Hamley, University of Reading, UK
Howard A. Stone, Princeton University, USA
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2: Hydrogels in Cell-based Therapies
3: Particle-stabilized Emulsions and Colloids: Formation and Applications
4: Fluid–Structure Interactions in Low-Reynolds-Number Flows
5: Non-wettable Surfaces: Theory, Preparation and Applications
6: Wormlike Micelles: Advances in Systems, Characterisation and
Applications
7: Electrospinning: From Basic Research to Commercialization
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Electrospinning
From Basic Research to Commercialization
Edited by
Erich Kny
KEMYK, Burgenland, Austria
Email: [email protected]
Kajal Ghosal
Dr B. C. Roy College of Pharmacy and Allied Health Services, Durgapur, India
Email: [email protected]
and
Sabu Thomas
Mahatma Gandhi University, Kottayam, India
Email: [email protected]
Soft Matter Series No. 7
Print ISBN: 978-1-78801-100-6
PDF ISBN: 978-1-78801-294-2
EPUB ISBN: 978-1-78801-491-5
Print ISSN: 2048-7681
Electronic ISSN: 2048-769X
A catalogue record for this book is available from the British Library
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Preface
This book revolves around the central theme of electrospinning, and discusses
in greater detail the recent developments in design, process parameters, poly-
mer selection, application areas and alternative electrospinning processes.
Electrospinning produces continuous ultrafine fibers in the semi-micro to
nano-diameter range from polymer solution/melt with the help of an elec-
trostatic force. The technology was first patented by Formhals in 1931 and
since then a series of technological advancements has established it as one
of the most popular semi-micro to nano-fabrication processes. In the past few
decades, electrospun non-woven matrices/membranes have been successfully
exploited by researchers across a wide variety of applications including tissue
engineering, nanocatalysis, clothing, biomedical/pharmaceutical/healthcare,
filtration, optical electronics, biosensors, defense and environmental protec-
tion, just to name a few. In contrast to existing literature and books available
on electrospinning and nanofibers, which are introductory and more funda-
mental in nature, this book focuses on recent developments in various aspects
of the electrospinning process. The primary target is to encompass various
approaches for successful implementation of this fabrication process towards
commercialization from basic research and development.
The book has 10 chapters. In Chapter 1, the historical journey of the electro-
spinning process towards its establishment in laboratory practice is explained.
Although fine fibers made by electrostatic force have been discussed, inves-
tigated and patented for a long time, until the 1980s potential applications
for such fibers were restricted by different technological limitations. In 1995,
Doshi and Reneker reworked and simplified the electrical spinning process.
The first chapter details these historical developments. Chapter 2 discusses the
encroachment of traditional electrospinning by process modifications. Higher
fiber production rates, better alignment, and uniform diameter of fibers can

Soft Matter Series No. 7
Electrospinning: From Basic Research to Commercialization
Edited by Erich Kny, Kajal Ghosal and Sabu Thomas
© The Royal Society of Chemistry 2018
Published by the Royal Society of Chemistry, www.rsc.org
v
vi Preface
only be achieved by continuous improvements of the electrospinning process.
Chapter 3 deals with electrospun composites that are biocompatible and bio-
active in nature. Their uses, compatibilization strategies, possible modifications,
utilization and recent commercialization are discussed. Chapter 4 discusses cell
electrospinning and technology transfer from lab to market scale. The authors
describe methods, challenges, opportunities, current research works, key
aspects and market potentials of cell electrospinning in this chapter. Chapter 5
is about health care and wound care textiles obtained through the electrospin-
ning process. A detailed discussion of their recent developments, essential
aspects, basic functions, specific characteristics, market potentials, and recent
success is presented. This chapter is focused on the applications of electrospin-
ning techniques specific to nanomedicine. Chapter 6 focuses on several gen-
eral methods of bioprinting, with an emphasis on hybrid systems that involves
both 3D printing and electrospinning. Future improvements in bioprinting
technologies and indications on potential markets are summarized. Chapter 7
is about the industrial applications of super-hydrophobic surfaces obtained
through electrospinning processes on a large scale in filtration/sorbents appli-
cations. Electrospun mats have unique properties that make them suitable for
water filtration, oil clean-ups and greenhouse gas sorbents. This chapter pres-
ents various materials and methods used for this purpose and comments on
the large-scale production feasibility of electrospun fibers. In Chapter 8, the
authors discuss the perspectives of the electrospinning process for electronics
and sensors. Chapter 9 shows that electrospinning has opened up new appli-
cations in energy applications such as proton exchange membrane fuel cells
and water electrolysis, etc. This chapter describes the recent advancements in
the field along with the materials used, methods applied, and future appli-
cation possibilities. Chapter 10 discusses recent developments and the latest
trends in packaging involving electrospun ultrathin fibers, focusing on their
technological impact and its potential scale-up and market introduction.
We hope that we have presented our theme in a very easy, understandable
and continuous manner. The contributing authors are experts in their par-
ticular fields and come from different parts of the world. To gain commercial
insight not just from academia, authors from industry are also involved.
We thank and acknowledge the kind assistance of our reviewers, whose
timely review and expert comments have helped us in accomplishing our
goal. We would also like to thank Connor Shephard and Leanne Marle for
their editorial assistance. We also take the opportunity to thank Dr Hanna
Maria and Dr Aniruddha Chandra who helped to form the initial proposal.
A further acknowledgment goes to the COST Networking Action MP1206 on
electrospinning, which was helpful in promoting the technological basis,
especially for Chapters 1, 2, 9 and 10, for describing and elucidating the latest
trends in these application fields.
Erich Kny, Kajal Ghosal and Sabu Thomas
Contents
Chapter 1 Electrical Spinning to Electrospinning: a Brief History 1
K. Ghosal, C. Agatemor, N. Tucker, E. Kny and S. Thomas
1.1 Introduction to Early Concepts, Phenomena and
Technology Related to Electrospinning 1
1.1.1 Initial Identity of Triboelectric
Charge and the Consequences for
Electrohydrodynamic Processes 1
1.1.2 The Development of Industrial
Spinning Processes 3
1.2 The Establishment of Electrospinning
for Fiber Generation 5
1.3 Current Status of the Electrospinning Process
in Materials Science and Engineering 12
1.4 Conclusion 16
References 17
Chapter 2 Encroachment of Traditional Electrospinning 24
I. Savva and T. Krasia-Christoforou
2.1 Introduction 24
2.2 Encroachment of Traditional Electrospinning
Towards Commercialization 26
2.2.1 Syringes Connected in Series 27
2.2.2 Gas-assisted Electrospinning/
Electroblowing 30
2.2.3 Needleless Electrospinning 31

Soft Matter Series No. 7
Electrospinning: From Basic Research to Commercialization
Edited by Erich Kny, Kajal Ghosal and Sabu Thomas
© The Royal Society of Chemistry 2018
Published by the Royal Society of Chemistry, www.rsc.org
vii
viii Contents
2.3 Electrospinning Encroachment in Fiber
Deposition, Morphology and 3D Structure
Development 36
2.3.1 Fiber Deposition 36
2.3.2 Morphology 43
2.3.3 3D Structure Development 47
2.4 Conclusion 49
Acknowledgements 49
References 49
Chapter 3 Biomimetic Electrospun Composites: from
Fundamental Insights to Commercialization 55
E. Mele
3.1 Introduction 55
3.2 Liquid-repellent Electrospun Fibers 58
3.2.1 Overview of Wetting Theories 58
3.2.2 Surfaces and Membranes with
Engineered Wettability 60
3.2.3 Commercially-available Products 65
3.3 Scaffolds for Tissue Engineering 66
3.3.1 Bone TE 66
3.3.2 Skin TE 71
3.3.3 Commercially-available Products 74
3.4 Conclusions 74
References 75
Chapter 4 Cell Electrospinning and Technology Transfer
from Lab to Market Scale 79
A. Townsend-Nicholson and S. N. Jayasinghe
4.1 Introduction 79
4.2 Tissue Engineering and the Construction
of 3D Biological Architectures 81
4.2.1 3D Printing/Biofabrication 82
4.2.2 Aerodynamically-assisted Biojets
and Threads 82
4.2.3 Jet-based Techniques 83
4.2.4 Is Cell Electrospinning Really
the Answer? 84
4.3 Cell Electrospinning: from Concept to Lab 85
4.4 Cell Electrospinning: from Lab to Market 87
4.4.1 Further Technical Refinements 88
4.4.2 Interrogation of Cell Electrospun
Structures 90
4.4.3 Getting to Market 91
Contents ix
4.5 Future Developments and Conclusion 92
Acknowledgements 92
References 92
Chapter 5 Electrospun Fibers for Advanced Wound Care:
Moving from Novel Lab-scale Curiosities to
Commercial Realities 95
H. Kriel, M. P. Coates and A. E. Smit
5.1 Introduction to Electrospun Fibers for
Advanced Wound Care 95
5.2 Advanced Wound Care and Nanomedicine:
the Research 98
5.2.1 Electrospun Fibers for Wound Care
Dressings 98
5.2.2 Electrospun Fibers for Nanomedicine 106
5.2.3 Electrospun Fibers for Healthcare
Diagnostics and Point-of-care 111
5.2.4 Modulation and Characterization of
Cell–Fiber Interactions 113
5.3 The Market: From Lab-scale Curiosities to
Commercial Realities 115
5.3.1 Overview 115
5.3.2 Electrospun Fiber Product
Development for Commercial
Advanced Wound Care 116
5.3.3 Regulatory Pathway for Electrospun
Fiber-based Advanced Wound Care
Products 120
5.4 Conclusion: the Future 122
References 123
Chapter 6 Electrospinning and 3D Printing: Prospects
for Market Opportunity 136
S. Saghati, Abolfazl Akbarzadeh, A. R. Del
Bakhshayesh, R. Sheervalilou and Ebrahim Mostafavi
6.1 Introduction 136
6.2 Materials for 3D Bioprinting 137
6.2.1 Bioinks 137
6.2.2 Cells 139
6.3 Bioprinting Techniques 139
6.3.1 Laser-assisted Printing 140
6.3.2 Extrusion Printing 141
6.3.3 Inkjet Printing 141
6.3.4 Hybrid Bioprinting 142