Although bone-patellar tendon-bone (B-PT-B) autografts are the gold standard for repair of anterior cruciate ligament ruptures, they suffer from drawbacks such as donor site morbidity and limited supply. Engineered tissues modeled after B-PT-B autografts are promising alternatives because they have the potential to regenerate connective tissue and facilitate osseointegration. Towards the long-term goal of regenerating ligaments and their bony insertions, the objective of this study was to construct 2D meshes and 3D cylindrical composite scaffolds - possessing simultaneous region-wise differences in fiber orientation, diameter, chemistry and mechanical properties - by electrospinning two different polymers from off-set spinnerets. Using a dual drum collector, 2D meshes consisting of an aligned polycaprolactone (PCL) fiber region, randomly oriented poly(lactide-co-glycolide) (PLGA) fiber region and a transition region (comprised of both PCL and PLGA fibers) were prepared, and region-wise differences were confirmed by microscopy and tensile testing. Bone marrow stromal cells (BMSCs) cultured on these meshes exhibited random orientations and low aspect ratios on the random PLGA regions, and high aspect ratios and alignment on the aligned PCL regions. Next, meshes containing an aligned PCL region flanked by two transition regions and two randomly oriented PLGA regions were prepared and processed into 3D cylindrical composite scaffolds using an interpenetrating photo-crosslinkable polyethylene glycol diacrylate hydrogel to recapitulate the shape of B-PT-B autografts. Tensile testing indicated that cylindrical composites were mechanically robust, and eventually failed due to stress concentration in the aligned PCL region. In summary, this study demonstrates a process to fabricate electrospun meshes possessing region-wise differences in properties that can elicit region-dependent cell responses, and be readily processed into scaffolds with the shape of B-PT-B autografts.

Electrospinning of polyesters (e.g. polycaprolactone) is an attractive approach for fabricating meshes with mechanical properties suitable for orthopedic tissue engineering applications. However, the resultant fused-fiber meshes are biologically inert, necessitating surface grafting of bioactive factors to stimulate cell adhesion. In this study, hydrophilic meshes displaying primary amine groups were prepared by coaxially electrospinning fibers with a chitosan/poly(ethylene oxide) shell and a polycaprolactone core. These chitosan–polycaprolactone fiber meshes were mechanically robust (Young’s modulus of 10.1 ± 1.6 MPa under aqueous conditions) with tensile properties comparable to polycaprolactone fiber meshes. Next, the integrin adhesion peptide arginine–glycine–aspartic acid was grafted to chitosan–polycaprolactone fiber meshes. Cell culture studies using bone marrow stromal cells indicated significantly better initial attachment and spreading on arginine–glycine–aspartic acid–conjugated fiber meshes. Specifically, metabolic activity, projected cell area, and cell aspect ratio were all elevated relative to cells seeded on polycaprolactone and unmodified chitosan–polycaprolactone meshes. These results demonstrate a flexible two-step process for creating bioactive electrospun fiber meshes.