An artificial spinning system using regenerated silk fibroin solutions is adopted to produce high-performance silk fibers. In previous studies, alcohol-based agents, such as methanol or ethanol, were used to coagulate silk dope solutions, producing silk fiber with poor mechanical properties compared with those of native silk fibers. The alcohol-based coagulation agents induce rapid β-sheet crystallization of the silk molecules, which inhibits subsequent alignment of the β-sheet crystals. Here, we induce gradual β-sheet formation to afford adequate β-sheet alignment similar to that of native silk fiber. To this aim, we developed an amorphous silk fiber spinning process that prevents fast β-sheet formation in silk molecules by using tetrahydrofuran (THF) as a coagulation solvent. In addition, we apply postdrawing to the predominantly amorphous silk fibers to induce β-sheet formation and orientation. The resultant silk fibers showed a 2.5-fold higher extensibility, resulting in 1.5-fold tougher silk fibers compared with native Bombyx mori silk fiber. The amorphous silk fiber spinning process developed here will pave the way to the production of silk fibers with desired mechanical properties.

Spider dragline silks have attracted intensive attention as eco-friendly tough materials because of their excellent mechanical property and biomass-based origin. Composite films based on a recombinant spider dragline silk protein (ADF3) from Araneus diadematus were prepared by doping with linear or telechelic poly(l-alanine) (L- or T-polyA, respectively) as a reinforcing agent. Higher tensile strength and toughness of the composite films were achieved with the addition of polyA compared with the tensile strength and toughness of the silk-only film. The difference in the reinforcing behavior between L- and T-polyA was associated with their primary structures, which were revealed by wide angle X-ray diffraction analysis. L-polyA showed a tendency to aggregate in the composite films and induce crystallization of the inherent silk β-sheet to afford rigid but brittle films. By contrast, T-polyA dispersion in the composite films led to the formation of β-sheet crystal of both T-polyA and the inherent silk, which imparted high strength and toughness to the silk films.