ELECTROSPINNING ROBOT FOR REGENERATIVE COATING OF IMPLANTS

Abstract

Electrospinning of nanofibrous mats and scaffolds enables generation of scaffolding that is not only highly porous, but also has a structure that essentially mimics the natural basement membrane. As a result, the method has proliferated extensively, and is commonly used for diverse applications such as water filtration or tissue engineering, the latter of which may involve the use of natural or synthetic materials. Common laboratory scale electrospinning setups can be built inexpensively with merely a syringe pump, a high voltage supply, and an aluminum foil target. These systems, however, are limited to flat target surface geometries that span several centimeters. While a scaffold can be cut or folded to conform to a bone or other biological surface, spinning directly onto a surface with significant peaks and troughs results in poor fiber uniformity. Furthermore, if an alteration of fiber properties is preferred, the high voltage setup limits user access and customization of parameters during the spinning period. Finally, control of the electric field is compromised by the proximity of grounded electrical components. As its first aim, this project develops a robotic control system to enable custom coatings of arbitrary surfaces. By augmenting the traditional electrospinning system with a three-dimensional robotic control system, electric field focusing fibers, and additional aerodynamic forces terms ‘electroblowing’, the device can be produced across targets with strong topographic anisotropy. The second aim continues to enhance these attributes with biocompatible soy based scaffolds. Craniofacial implants are often complex in geometry, and conformal bandages are particularly hard to produce in these areas. Soy based scaffolds will be produced for 3D-printed replicas of these situations. Finally, the methods developed across this aim enables the development and use of a handheld electrospinning system that combines a coaxial high velocity air flow with the high voltage spinning element to reduce effects of operator error. The final goal of the thesis is to test whether fiber control successfully reduces effects of fiber anisotropy in vitro and to use the enhanced fiber control mechanisms to produce scaffolds with significant anisotropy, depositing aligned fibers at a target point to eventually enable generation of scaffolds with programmable variable spatial alignment similar to tendon. When completed, the systems described will enable custom production of coatings or scaffolds for functionality as scaffolding on medically relevant surfaces. Specifically, this means first, that scaffolds can be used with confidence to improve fixation even of non-cylindrical implants and enhance local tissue integration, and second, that implants can be customized with areas of ‘guidance’ fibers or local drug depots to either promote regeneration and population by surrounding tissue or mimic natural anisotropic cues necessary for mechanical or biological functionality.