Abstract.Highly porous poly (ε-caprolactone) microfiber scaffolds can be fabricated using electrospinning for tissue engineering applications. Melt electrospinning produces such scaffolds by direct deposition of a polymer melt instead of dissolving the polymer in a solvent as performed during solution electrospinning. The objective of this study was to investigate the significant parameters associated with the melt electrospinning process that influence fiber diameter and scaffold morphology, including processing temperature, collection distance, applied voltage and nozzle size. The mechanical properties of these microfiber scaffolds varied with microfiber diameter. Additionally, the porosity of scaffolds was determined by combining experimental data with mathematical modeling. To test the cytocompatability of these fibrous scaffolds, we seeded neural progenitors derived from murine R1 embryonic stem cell lines onto these scaffolds where they could survive, migrate, and differentiate into neurons, demonstrating the potential of these melt electrospun scaffolds for tissue engineering applications.

In this study, we investigated the effect of micro and nanoscale scaffold topography on promoting neuronal differentiation of human induced pluripotent stem cells (iPSCs) and directing the resulting neuronal outgrowth in an organized manner. We used melt electrospinning to fabricate poly (ε‐caprolactone) (PCL) scaffolds with loop mesh and biaxial aligned microscale topographies. Biaxial aligned microscale scaffolds were further functionalized with retinoic acid releasing PCL nanofibers using solution electrospinning. These scaffolds were then seeded with neural progenitors derived from human iPSCs. We found that smaller diameter loop mesh scaffolds (43.7 ± 3.9 µm) induced higher expression of the neural markers Nestin and Pax6 compared to thicker diameter loop mesh scaffolds (85 ± 4 µm). The loop mesh and biaxial aligned scaffolds guided the neurite outgrowth of human iPSCs along the topographical features with the maximum neurite length of these cells being longer on the biaxial aligned scaffolds. Finally, our novel bimodal scaffolds also supported the neuronal differentiation of human iPSCs as they presented both physical and chemical cues to these cells, encouraging their differentiation. These results give insight into how physical and chemical cues can be used to engineer neural tissue. © 2014 Wiley Periodicals, Inc. J Biomed Mater Res Part A: 103A: 2591–2601, 2015.

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Melt electrospinning creates fibrous scaffolds using direct deposition. The main challenge of melt electrospinning is controlling the topography of the scaffolds for tissue engineering applications. Mathematical modeling enables a better understanding of the parameters that determine the topography of scaffolds. The objective of this study is to build two types of mathematical models. First, we modeled the melt electrospinning process by incorporating parameters such as nozzle size, counter electrode distance and applied voltage that influence fiber diameter and scaffold porosity. Our second model describes the accumulation of the extruded microfibers on flat and round surfaces using data from the microfiber modeling. These models were validated through the use of experimentally obtained data. Scanning electron microscopy (SEM) was used to image the scaffolds and the fiber diameters were measured using Quartz-PCI Image Management Systems® in SEM to measure scaffold porosity.