Green manufacturing has emerged across industries, propelled by a growing awareness of the negative environmental and health impacts associated with traditional practices. In the biomaterials industry, electrospinning is a ubiquitous fabrication method for producing nano- to micro-scale fibrous meshes that resemble native tissues, but this process traditionally utilizes solvents that are environmentally hazardous and pose a significant barrier to industrial scale-up and clinical translation. Applying sustainability principles to biomaterial production, we have developed a ‘green electrospinning’ process by systematically testing biologically benign solvents (U.S. Food and Drug Administration Q3C Class 3), and have identified acetic acid as a green solvent that exhibits low ecological impact (global warming potential (GWP) = 1.40 CO2 eq. kg/L) and supports a stable electrospinning jet under routine fabrication conditions. By tuning electrospinning parameters, such as needle-plate distance and flow rate, we updated the fabrication of widely utilized biomedical polymers (e.g. poly-α-hydroxyesters, collagen), polymer blends, polymer-ceramic composites, and growth factor delivery systems. Resulting ‘green’ fibers and composites are comparable to traditional meshes in terms of composition, chemistry, architecture, mechanical properties, and biocompatibility. Interestingly, material properties of green synthetic fibers are more biomimetic than those of traditionally electrospun fibers, doubling in ductility (91.86 ± 35.65 vs. 45 ± 15.07%, n = 10, p < 0.05) without compromising yield strength (1.32 ± 0.26 vs. 1.38 ± 0.32 MPa) or ultimate tensile strength (2.49 ± 0.55 vs. 2.36 ± 0.45 MPa). Most importantly, green electrospinning proves advantageous for biofabrication, rendering a greater protection of growth factors during fiber formation (72.30 ± 1.94 vs. 62.87 ± 2.49% alpha helical content, n = 3, p < 0.05) and recapitulating native ECM mechanics in the fabrication of biopolymer-based meshes (16.57 ± 3.92% ductility, 33.38 ± 30.26 MPa elastic modulus, 1.30 ± 0.19 MPa yield strength, and 2.13 ± 0.36 MPa ultimate tensile strength, n = 10). The eco-conscious approach demonstrated here represents a paradigm shift in biofabrication, and will accelerate the translation of scalable biomaterials and biomimetic scaffolds for tissue engineering and regenerative medicine.

Pectin, a natural biopolymer mainly derived from citrus fruits and apple peels, shows excellent biodegradable and biocompatible properties. This study investigated the electrospinning of pectin-based nanofibers. The parameters, pectin:PEO (polyethylene oxide) ratio, surfactant concentration, voltage, and flow rate, were studied to optimize the electrospinning process for generating the pectin-based nanofibers. Oligochitosan, as a novel and nonionic cross-liker of pectin, was also researched. Nanofibers were characterized by using AFM, SEM, and FTIR spectroscopy. The results showed that oligochitosan was preferred over Ca 2+ because it cross-linked pectin molecules without negatively affecting the nanofiber morphology. Moreover, oligochitosan treatment produced a positive surface charge of nanofibers, determined by zeta potential measurement, which is desired for tissue engineering applications.

The synthesis and bottom-up assembly of nanocellulose by microbes offers unique advantages to tune and meet key design criteria—rapid renewability, low toxicity, scalability, performance, and degradability—for multi-functional, circular economy textiles....

Harnessing microbial biofabrication and inspired by indigenous practices, we engineer high-performance microbial nanocellulose (MC) biotextiles with a sustainable circular life cycle. Specifically, our plant-based lecithin phosphocholine treatment modulates cellulose cross-linking through phosphate and methylene groups, to yield a biodegradable material with superior mechanical and flame-retardant properties. Coloration is achieved using natural dyes and waste-to-resource strategies. Life cycle impact assessment reveals MC biotextiles mitigate the carcinogenics of leather by a factor of 103 and the carbon footprint of synthetic leather and cotton by ~97%, for widespread application in fashion, interiors, and construction. The translational potential of this approach is tremendous, as using microbes and green chemistry to engineer regenerative, high-performance products will disrupt linear production models and mitigate its environmental threats in a circular economy.