Silk fibroin sponges have been widely studied and reported in literature for tissue engineering applications. Several fabrication methods have been proposed during the years to cover most of the demands in terms of properties, which should be adapted to the considered tissue. Most of these procedures are based on the secondary structure transition of the protein to the stable β crystalline form. This transition, known as physical cross-linking, makes the sponge resistant to dissolution in water, and, in general, increases the sponge stiffness. In our work, we propose an alternative method to ensure the stability of the sponge based on chemical crosslinking of a methacrylated version of silk fibroin (Sil-MA) obtained via chemical modification. The Sil-MA water solution with the addition of a photoinitiator (LAP) allows the opening, under UV radiation, of a double carbon−carbon bond and radical polymerization. The incorporation of air bubbles (that serves as a template for the pores) was accomplished by a mixer; then, the foam was stabilized under UV light and the excess water was removed by freeze-drying. Because of the cytotoxicity of the photoinitiator (found when used at a high concentration), an additional washing step in water has been introduced to eliminate the residues and improve the cells' viability. Fourier transform infrared (FTIR) analysis confirmed the functionalization of the protein. To evaluate the effect of the composition on the sponge properties, a 2 3 full factorial design of the experiment has been adopted. FTIR analysis revealed that the sponge composition did not affect the protein's secondary structure. The analysis of images obtained by SEM allowed some statistical measures of the porosity curves to be studied and modeled. The same modeling procedure was applied to the dissolution test in a simulated body fluid, to the water absorption, and to the cell viability (tested by the MTT and LDH assays). An empirical model for each property was built, showing how by changing the composition it is possible to tune the sponge properties.

Silk fibroin is a protein with a unique combination of properties and is widely studied for biomedical applications. The extraction of fibroin (degumming) from the silk filament impacts the properties of the outcoming material. The degumming can be conducted with different procedures. Among them, the most used and studied procedure in the research field is the alkali degumming with sodium carbonate (Na2CO3). In this study, by the use of a statistical method, namely, design of experiment (DOE), we characterized the Na2CO3 degumming, taking into consideration the main process factors involved and changing them within a selected range of values. We considered the process temperature and time, the salt concentration, and the number of baths used, testing the impact of these variables on the fibroin properties by building empirical models. These models not only took into consideration the direct effect of the process factors but also their combined effect, which are not conventionally detectable with other methods. The weight loss and the amount of sericin removed in the process were determined and used as a measure of the effectiveness of the process. The secondary structure, the molecular weight, the diameter of fibers, and their morphology and mechanical properties were studied with the intent to correlate the macroscopical properties with the structural changes. We report, for the first time, the possibility to effectively remove all sericin from the silk fibroin using Na2CO3, using a process that requires less salt, water, and energy, in comparison with the standard alkali protocol, making this technique overall more environmentally sustainable; in addition, we have demonstrated the possibility to tune the material properties by varying the degumming conditions and even to optimize them with empirical statistically based equations that allow one to directly set the optimal process parameters. The major effect on the macroscopical properties (such as the ultimate strength and Young’s modulus) has been proved to be correlated with the removal of sericin instead of the microstructural variations. Finally, a ready-to-use table with a set of optimized degumming procedures to maximize or minimize the studied properties was provided.

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