Building
two-dimensional (2D) and three-dimensional (3D) fibrous
structures in the micro- and nanoscale will offer exciting prospects
for numerous applications spanning from sensors to energy storage
and tissue engineering scaffolds. Electrospinning is a well-suited
technique for drawing micro- to nanoscale fibers, but current methods
of building electrospun fibers in 3D are restrictive in terms of printed
height, design of macroscopic fiber networks, and choice of polymer.
Here, we combine low-voltage electrospinning and additive manufacturing
as a method to pattern layers of suspended mesofibers. Layers of fibers
are suspended between 3D-printed supports in situ in multiple fiber
layers and designable orientations. We examine the key working parameters
to attain a threshold for fiber suspension, use those behavioral observations
to establish a “fiber suspension indicator”, and demonstrate
its utility through design of intricate suspended fiber architectures.
Individual fibers produced by this method approach the micrometer/submicrometer
scale, while the overall suspended 3D fiber architecture can span
over a centimeter in height. We demonstrate an application of suspended
fiber architectures in 3D cell culture, utilizing patterned fiber
topography to guide the assembly of suspended high-cellular-density
structures. The solution-based fiber suspension patterning process
we report offers a unique competence in patterning soft polymers,
including extracellular matrix-like materials, in a high resolution
and aspect ratio. The platform could thus offer new design and manufacturing
capabilities of devices and functional products by incorporating functional
fibrous elements.