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This study presents first polymeric hollow fibers (HFs) with sufficient optical transparency for real‐time and non‐invasive monitoring of biological systems, one of the most important hurdles accounted in HF bioreactor technology. Biocompatible polymers, including polyvinylidene fluoride (PVDF), polycaprolactone, and polyacrylonitrile, were processed via dry‐jet wet spinning. A comprehensive analysis of the morphological, structural, and transport properties of the HFs provided valuable insights into their optical performance. Our findings revealed the critical interplay of HF wall thickness, porosity, polymer crystal size, and intrinsic refractive index in achieving transparency. These findings may serve as a useful guidance to produce transparent polymeric HFs with similar or different polymeric systems. Remarkably, PVDF HFs achieved over 83% transmittance, exceeding standards for in vitro cell observation, and was achieved without the presence of modifiers. As a proof of concept, labeled human cerebral microvascular endothelial cells (hCMEC/D3) were cultured within the HFs and successfully monitored in real time under both static and dynamic conditions. These transparent HFs demonstrate transformative potential, enabling real‐time decision making while significantly reducing cost and time. This cutting‐edge membrane material paves the way for advanced applications in microfluidics, mass transport studies, and biomedical research, establishing these transparent HFs as key enabling materials for strategic biomedical technologies. This work introduces the first demonstrative application of optically transparent polymeric hollow fibers to enable real‐time and non‐invasive observation of living cells cultured in their lumen. The results establish a new platform for faster, more cost‐effective, and more precise biomedical research, with applications in microfluidics and cell culture monitoring.

Cellulose, a natural, renewable, and environment friendly biopolymer, has been considered as a sustainable feedstock in the near future. However, only 0.3% of cellulose is today processed since it is not soluble in conventional solvents due to the strong hydrogen bonding network and highly ordered structure. Hence, the search of effective and eco-friendly solvents for cellulose dissolution has been a key pillar for decades. In the recent years, ionic liquids (ILs) have been proposed as green solvents for cellulose and have been applied for the production of cellulose-based fibers. This review aims to focus the attention toward fiber spinning methods of cellulose based on ILs, as well as recent progress in cellulose dissolution using ILs. Moreover, the development of cellulosic fibers blended with other biopolymers, and cellulose composites are presented. Finally, different applications of cellulose fibers and composites are summarized and discussed.

Ioncell-F, a recently developed process for the production of man-made cellulosic fibers from ionic liquid solutions by dry-jet wet spinning, is presented as an alternative to the viscose and N-methylmorpholine N-oxide (NMMO)-based Lyocell processes. The ionic liquid 1,5-diazabicyclo[4.3.0]non-5-ene acetate was identified as excellent cellulose solvent allowing for a rapid dissolution at moderate temperatures and subsequent shaping into continuous filaments. The highly oriented cellulose fibers obtained upon coagulation in cold water exhibited superior tenacity, exceeding that of commercial viscose and NMMO-based Lyocell (Tencel®) fibers. The respective staple fibers, which have been converted into two-ply yarn by ring spinning technology, presented very high tenacity. Furthermore, the Ioncell yarn showed very good behavior during the knitting and weaving processes, reflecting the quality of the produced yarn. The successfully knitted and woven garments from the Ioncell yarn demonstrate the suitability of this particular ionic liquid for the production of man-made cellulosic fibers and thus give a promising outlook for the future of the Ioncell-F process.

We report on a new process for the spinning of high-performance cellulosic fibers. For the first time, cellulose has been dissolved in the ionic liquid (IL) 1-ethyl-3-methylimidazolium octanoate ([C2C1im][Oc]) via a thin film evaporator in a continuous process. Compared to other ILs, [C2C1im][Oc] shows no signs of hydrolysis with water. For dope preparation the degree of polymerization of the pulp was adjusted by electron beam irradiation and determined by viscosimetry. In addition, the quality of the pulp was evaluated by means of alkali resistance. Endless filament fibers have been spun using dry-jet wet spinning and an extruder instead of a spinning pump, which significantly increases productivity. By this approach, more than 1000 m of continuous multifilament fibers have been spun. The novel approach allows for preparing cellulose fibers with high Young's modulus (33 GPa) and unprecedented high tensile strengths up to 45 cN/tex. The high performance of the obtained fibers provides a promising outlook for their application as replacement material for rayon-based tire cord fibers.

In recent years, the search for alternatives to petroleum derived products, such as plastic films, has become a priority due to the growing depletion of fossil reserves and the pollution of water resources by microplastics, microscopically small plastic particles which are harmful to ocean and aquatic life. Cellulose-based films, e.g., cellophane and cuprophane, have been on the market for almost a century. Despite being a more ecological option compared to plastic films, the manufacture of these cellulose films involves high production costs and the use of harmful chemicals. As an alternative, a sustainable and eco-friendly process based on the Lyocell-type Ioncell® technology is presented to produce cellulose films. Regenerated cellulose films are created by continuous extrusion via dry-jet wet spinning of an ionic liquid–cellulose solutions. The influence of the polymer concentration (8–13 wt%) and processing temperature (50–100 °C) on the properties of the films were studied by the determination of the thickness, mechanical properties, physical appearance, morphology, chemical composition, and hydrophobicity. The obtained films are thin (12–21 μm), transparent (transmittance = 91%) and of homogeneous structure. Moreover, they exhibit excellent mechanical properties: stress values up to 210 MPa and elongations up to 19% in machine (longitudinal) direction. These values clearly outperform commercial cellophane, which presents stress values of 125 MPa and elongations of 22%. The films presented herein hold great potential to become an eco-friendly and sustainable option to commercial films.

Bacterial cellulose, as an important renewable bioresource, exhibits excellent mechanical properties along with intrinsic biodegradability. It is expected to replace non-degradable plastics and reduce severe environmental pollution. In this study, using dry jet-wet spinning and stretching methods, we fabricate cellulose composite macrofibers using nanofibrillated bacterial cellulose (BCNFs) which were obtained by agitated fermentation. Ionic liquid (IL) was used as a solvent to perform wet spinning. In this process, force-induced alignment of BCNFs was applied to enhance the mechanical properties of the macrofibers. The results of scanning electron microscopy revealed the well-aligned structure of BCNF along the fiber axis. The fiber prepared with an extrusion rate of 30 m min−1 and a stretching ratio of 46% exhibited a strength of 174 MPa and a Young’s modulus of 13.7 GPa. In addition, we investigated the co-spinning of carboxymethyl cellulose-containing BCNF with chitosan using IL as a “container”, which indicated the compatibility of BCNFs with other polysaccharides. Recycling of the ionic liquid was also verified to validate the sustainability of our strategy. This study provides a scalable method to fabricate bacterial cellulose composite fibers, which can be applied in the textile or biomaterial industries with further functionalization.

The microstructure of polyacrylonitrile (PAN) precursor fibers has a profound influence on the performance of carbon fibers and depends on the spinning processes and processing conditions. This study compared the evolution of the microstructures and performance of PAN fibers between the wet-spinning and dry-jet wet-spinning processes, utilizing scanning electron microscopy, small/wide-angle X-ray scattering, dynamic mechanical analysis, and single-fiber tensile testing. Both spinning processes promoted the oriented alignment of microfibrils and fibrils, improved the crystal arrangement and molecular regularity, and facilitated the transition from a two-phase (crystalline/amorphous) structure to a single-phase structure, thereby gradually improving the fibers’ elastic character and mechanical properties. However, wet-spun fibers exhibited inherent defects (skin-core structure and large voids), which caused surface grooves, radial mechanical heterogeneity, and low breaking elongation during post-spinning. In contrast, dry-jet wet-spun fibers initially had a smooth surface and a homogeneous radial structure, which evolved into well-oriented, radially homogeneous structures during post-spinning. Furthermore, the dry-jet wet-spinning process produced greater increases in crystallinity (46%), crystal size (258%), and orientation index (146%) than the wet-spinning process did. The dry-jet wet-spinning process’s superiority in forming and optimizing the fiber microstructure gives it greater potential for producing high-quality PAN precursor fibers.

Hemicellulose-rich pulp raw materials are avoided in the production of man-made cellulosic textile fibres due to hemicellulose reactivity with the currently used industrial solvent systems. Incorporation of hemicelluloses in regenerated fibres could, however, increase the share of used wood biomass and thus improve the environmental footprint of regenerated fibre products. Superbase ionic liquids have shown potential in dissolving and regenerating all the major wood polymers i.e. cellulose, hemicellulose and lignin into regenerated products. In this work, regenerated fibres were spun from hemicellulose-rich softwood and eucalyptus paper-grade pulps and eucalyptus dissolving pulp using a superbase ionic liquid [mTBNH][OAc]. Before dissolution and spinning, intrinsic viscosities of the paper-grade pulps were adjusted either enzymatically or by using a mild acid-treatment to improve dope rheology for dry-jet wet spinning. In fibre spinning, hemicellulose was found to regenerate in high yield and the obtained regenerated fibres had high dry tenacities (5.3 to 15 cN/dtex). The best mechanical properties were measured from fibres with high hemicellulose content (17.3% (w/w)). Pulp pretreatment was found to be critical for achieving good mechanical properties. Acid-pretreatment, which modified both cellulose and hemicellulose, yielded regenerated fibres with better mechanical properties compared to an enzyme-pretreatment which did not alter the hemicellulose structure. Removal of hemicellulose substituents and hydrolysis of hemicellulose backbone in acid-pretreatment may be the key to improved mechanical properties in hemicellulose-containing regenerated fibres. Enzymatic peeling and imaging with a xylan-specific monoclonal antibody (CCRC-M138) suggest that hemicelluloses were enriched to the outermost layers of the regenerated fibres.

Sutures provide mechanical support for wound closure after various traumas and surgical operations. Absorbable sutures are increasingly favored as they eliminate the need for secondary procedures and minimize additional damage to the wound site. In this study, chitosan sutures were produced using the dry jet–wet spinning method, achieving number 7-0 sutures (approximately 76 μm diameter) with a homogeneous surface. FTIR analysis demonstrated molecular interactions between chitosan and TiO2 or curcumin, confirming successful incorporation. The addition of 3% TiO2 increased the tensile strength of chitosan sutures by 12.32%, reaching 189.41 MPa. Morphological analysis revealed smooth surfaces free of pores and bubbles, confirming the production of high-quality sutures. Radical scavenging activity analysis showed that curcumin-loaded sutures exhibited 43% scavenging ability after 125 h, which was significantly higher compared to pure chitosan sutures. In vitro antibacterial tests demonstrated that curcumin-loaded sutures provided 98.87% bacterial inactivation against S. aureus within 24 h. Additionally, curcumin release analysis showed a cumulative release of 77% over 25 h. The bioactivity of the sutures was verified by hydroxyapatite layer formation after incubation in simulated body fluid, supporting their potential for tissue regeneration. These findings demonstrate that TiO2 reinforcement and curcumin loading significantly enhance the functional properties of chitosan sutures, making them strong candidates for biocompatible and absorbable surgical applications.

Physical guidance cues play an important role in enhancing the efficiency of nerve conduits for peripheral nerve injury repair. However, very few in vivo investigations have been performed to evaluate the repair efficiency of nerve conduits with micro-grooved inner textures. In this study, polyacrylonitrile nerve conduits were prepared using dry-jet wet spinning, and micro-grooved textures were incorporated on the inner surface. The nerve conduits were applied to treat 10 mm sciatic nerve gaps in Sprague–Dawley (SD) rats. Sixteen weeks following implantation, nerve function was evaluated based on heat sensory tests, electrophysiological assessments and gastrocnemius muscle mass measurements. The thermal latency reaction and gastrocnemii weight of SD rats treated with grooved nerve conduits were almost 25% faster and 60% heavier than those of SD rats treated with smooth nerve conduits. The histological and immunohistochemical stain analyses showed the repair capacity of inner grooved conduits was found to be similar to that of autografts. These results suggest that grooved nerve conduits with groove width larger than 300 μm significantly improve peripheral nerve regeneration by introducing physical guidance cues. The obtained results can support the design of nerve conduits and lead to the improvement of nerve tissue engineering strategies.