Core-sheath electrospinning is a rapid microfabrication process for creating multi-layer polymer microfibers. This paper presents a process based on core-sheath electrospinning to fabricate poly(L-lactic acid) (PLLA) microtubes with nanopores on the tube wall. The morphology of the microtubes mimics human fenestrated capillary vessels. This study investigates the effects of the viscosities of the core and the sheath solutions on the microtube outer diameter and the nanopore size. The core solution shows a dominating influence on the microtube diameter. At the same core solution viscosity level, the microtube diameter is negatively correlated to the core-to-sheath viscosity ratio. The pore size is positively correlated to the microtube diameter. Understanding the effects of solution viscosity on microtube morphology is the prerequisite for process control and microtube product development for future biomedical applications.

The ability to create three-dimensional (3D) cell-incorporated constructs for tissue engineering has progressed tremendously. One of the major challenges that limit the clinical applications of tissue engineering is the inability to form sufficient vascularization of capillary vessels in the 3D constructs. The lack of a functional capillary network for supplying nutrients and oxygen leads to poor cell viability. This paper presents the near-field electrospinning (ES) technique to fabricate a branched microfiber structure that mimics the morphology of capillaries. Polycaprolactone solution was electrospun onto a sloped collector that resulted in morphological and geometric variation of the fibers. With proper control over the solution viscosity and the electrospinning voltage, a single fiber was scattered into a branched fiber network and then converged back to a single fiber on the collector. The obtained fibers have a diameter of less than 100 microns at the two ends with coiled and branched fibers of less than 10 microns that mimics the arteriole-capillary-venule structure. The formation of such a structure in the near-field ES strongly depends on the solution viscosity. Low viscosity solutions form beads and discontinuous lines thus cannot be used to achieve the desired structure. The branching of PCL fiber occurs due to an electrohydrodynamic instability. The transition from the straight large fiber to smaller coiled/branched fibers is not instantaneous and stretches over a horizontal region of 1.5 cm. The current work shows the feasibility of electrospinning the stem-branch-stem fibrous structure by adopting a valley-shaped collector with potentials for tissue engineering applications.

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