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).

Due to its excellent biocompatibility, Chitosan is a very promising material for degradable products in biomedical applications. The development of pure chitosan microfibre yarn with defined size and directional alignment has always remained a critical research objective. Only fibres of consistent quality can be manufactured into textile structures, such as nonwovens and knitted or woven fabrics. In an adapted, industrial scale wet spinning process, chitosan fibres can now be manufactured at the Institute of Textile Machinery and High Performance Material Technology at TU Dresden (ITM). The dissolving system, coagulation bath, washing bath and heating/drying were optimised in order to obtain pure chitosan fibres that possess an adequate tenacity. A high polymer concentration of 8.0–8.5% wt. is realised by regulating the dope-container temperature. The mechanical tests show that the fibres present very high average tensile force up to 34.3 N, tenacity up to 24.9 cN/tex and Young’s modulus up to 20.6 GPa, values much stronger than that of the most reported chitosan fibres. The fibres were processed into 3D nonwoven structures and stable knitted and woven textile fabrics. The mechanical properties of the fibres and fabrics enable its usage as textile scaffolds in regenerative medicine. Due to the osteoconductive properties of chitosan, promising fields of application include cartilage and bone tissue engineering.

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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The present study reports on the fabrication of new composite chitosan-based knitted three-dimensional textile scaffolds for regenerative medicine. A critical research objective remained the fabrication of pure chitosan microfiber yarn with defined size and directional alignment, which could lead to textile structure, for example, woven and/or knitted fabrics. The construction of such textile structure with pure chitosan fibers possessing adequate tensile strength was recently realized in our laboratory. In the combination of micro/nanofiber composites, one can benefit from both the strength provided by the woven/knitted structure of the microfiber and the cell-seeding ability of the spun nanofiber mesh. Therefore, chitosan knitted fabrics were functionalized with gelatin nanofibers producing new interfaces for cell seeding. Both, pure chitosan and chitosan/gelatin scaffolds were proved non-cytotoxic to fibroblasts. Moreover, in vitro test with osteoblasts culture was carried out in order to analyze the influence of the surfaces and interfaces of the functionalized textile scaffold on cell ingrowth and proliferation.

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