In this article, the benefits offered by micro-fibrous scaffold architectures fabricated by textile manufacturing techniques are discussed: How can established and novel fiber-processing techniques be exploited in order to generate templates matching the demands of the target cell niche? The problems related to the development of biomaterial fibers (especially from nature-derived materials) ready for textile manufacturing are addressed. Attention is also paid on how biological cues may be incorporated into micro-fibrous scaffold architectures by hybrid manufacturing approaches (e.g. nanofiber or hydrogel functionalization). After a critical review of exemplary recent research works on cell-free fiber based scaffolds for in situ TE, including clinical studies, we conclude that in order to make use of the whole range of favors which may be provided by engineered fibrous scaffold systems, there are four main issues which need to be addressed: (1) Logical combination of manufacturing techniques and materials. (2) Biomaterial fiber development. (3) Adaption of textile manufacturing techniques to the demands of scaffolds for regenerative medicine. (4) Incorporation of biological cues (e.g. stem cell homing factors).

The field of articular cartilage tissue engineering has developed rapidly, and chitosan has become a promising material for scaffold fabrication. For this paper, wet-spun biocompatible chitosan filament yarns were converted into short flock fibers and subsequently electrostatically flocked onto a chitosan substrate, resulting in a pure, highly open, porous, and biodegradable chitosan scaffold. Analyzing the wet-spinning of chitosan revealed its advantages and disadvantages with respect to the fabrication of the fiber-based chitosan scaffolds. The scaffolds were prepared using varying processing parameters and were analyzed in regards to their geometrical and mechanical properties. It was found that the pore sizes were adjustable between 65 and 310 µm, and the compressive strength was in the range 13–57 kPa.

Textile structures made of biocompatible, osteoconductive and resorbable chitosan-filaments provide excellent preconditions as scaffolds for Bone Tissue Engineering applications. The novel Net Shape Nonwoven (NSN) technique that enables short fibers to be processed into three-dimensional net-shaped nonwoven structures with adjustable pore size distributions is described. NSN scaffolds made of pure chitosan fibers were fabricated. NSN hybrid scaffolds for improved initial cell adhesion were realized by combining the NSN technique with electrospinning and dip-coating with collagen, respectively. Scanning electron microscopy and liquid displacement porosimetry revealed an interconnecting open porous scaffold structure. The novel chitosan-hybrid scaffolds provide proper conditions for adhesion, proliferation and differentiation of the seeded human bone marrow stromal cells, proving that they are suitable for usage in hard-tissue regeneration.

One possibility to improve the mechanical properties after tendon ruptures is augmentation with a scaffold. Based on wet spinning technology, chitosan fibres were processed to a novel pure high-grade multifilament yarn with reproducible quality. The fibres were braided to obtain a 3D tendon scaffold. The CS fibres and scaffolds were evaluated biomechanically and compared to human supraspinatus (SSP) tendons. For the cytobiological characterization, in vitro cell culture experiments with human mesenchymal stem cells (hMSC) were performed. Three types of 3D circular braided scaffolds were fabricated. Significantly, higher ultimate stress values were measured for scaffold with larger filament yarn, compared to scaffold with smaller filament yarn. During cultivation over 28 days, the cells showed in dependence of isolation method and/or donor a doubling or tripling of the cell number or even a six-fold increase on the CS scaffold, which was comparable to the control (polystyrene) or in the case of cells obtained from human biceps tendon even higher proliferation rates. After 14 days, the scaffold surface was covered homogeneously with a cell layer. In summary, the present work demonstrates that braided chitosan scaffolds constitute a straightforward approach for designing tendon analogues, maintaining important flexibility in scaffold design and providing favourable mechanical properties of the resulting construct.

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