Melt Electrospinning by Spraybase®

Interested in Creating 3D Structures with a Low Micron Fiber Diameter? Want to achieve a smaller pore size? Need a solvent free process?

Our Spraybase® Melt Electrospinning, instrument, which will enable your team to create the 3D structures you desire for your tissue engineering needs is here!


About

What is Melt Electrospinning?

Melt Electrospinning is a new and revolutionary technique that bridges the gap between current additive manufacturing, such as 3D printing and solution electrospinning. Melt electrospinning is a form of electrospinning where a polymer melt is used to form fibrous material. [1]  Melt Electrospinning typically produces microfibers in the range of 5-40 um, although this technology has been shown to produce sub-micron diameter fibers. [2] Within the field of regenerative medicine this is highly advantageous as melt electrospinning can produce fibres with higher resolution compared to 3D printing. For controlled deposition of 3D scaffolds with programmable porosity and alignment requirements. It also overcomes the negative requirements of solution electrospinning, toxic solvents are not required within the process. Check out our recent poster on MEW here.

Spraybase® new melt electrospinning instrument will enable the production of 3D scaffolds for your tissue engineering needs

Features

  • Ease and Flexibility of Use.: We have created a G-code programme to convert your specific grid into the G-code required to create your scaffold
  • Melting Temperature: 25-250 °Celsius
  • Translational speed: The X-Y-Z translational component has a maximum speed of 8,000 mm/min to create alignment in your fibers
  • Safety:  High voltage interlock to protect end user

What's included in your Melt Electrospinning system?

melt+electrospinning+spraybase
  • 20kV Power Source
  • Melt head with 5g volume capacity
  • Pressure Driven fluidic control system to deliver molten liquid to emitter tip
  • X-Y-Z translational stage
  • Flat Plate Collector
  • Emitter
  • Safety Cover with high voltage interlock

Additional extras:

  • Camera and visualisation software

 

You can see visual demonstrations on our videos section. 


How does Melt Electrospinning Work?

Spraybase® has designed a Melt Electrospinning instrument that can melt a range of polymers between 25 to 250°C directly from their pellet/powder/flake composition. The polymer is placed within a syringe and heated to a desirable temperature. Once the melted polymer is present at the emitter tip , air pressure is used to control the flow rate of the polymer melt. Due to the lack of solvents used, the conductivity of the polymer is much lower. This is beneficial in ways as the electrospun jets produced have reduced ‘whipping’ enabling increased control on the fibre deposition. Due to the lower conductivity, polymers are electrospun at closer distances. A threshold voltage is induced which causes the polymer particles to become charged and form a Taylor cone. Due to high chain entanglement within the polymer structure a jet is produced which elongates within the electric field to deposit onto the collector. For additional control of scaffold structure, the designed instrument has a software  controlled X-Y-Z stage. This enables the  user to direct write the polymer fibres to deposit their desired structure. 


Advantages of Melt Electrospinning

The electrofied molten jet is not subject to the ’whipping motion’ observed in solution electrospinning, leading to a greater control over the deposition of the fiber. [3] Additionally, during deposition the fibers do not repel each other. These advantages are attributed to the elimination of solvent in this process. With no solvent needed for this process it also has implications for the overall application, as residual solvent does not need to be removed before using the desired scaffold on cells or in vivo. Melt electrospun fibers have been directly deposited onto cells showing no issues with cell viability. [4]  The Spraybase® Melt Electrospinning instrument is designed so that your own proprietary polymer, medical grade or laboratory grade polymers can be used as received. 

If you are interested in a solvent free technology that can enable you to create a 3D scaffold with  fiber diameters in the sub-micron to 50 um range to enable you to create a specific pore size to meet your engineering needs speak with us or receive a quote  for our NEW Spraybase® Melt Electrospinning instrument contact us today.


Technical Specifications 

General Description
Model The MELT by Spraybase® CAT000111
Description Melt electrospinning instrument
Spinning Type Top-Down
Produced In Ireland
High Voltage Power Supply
Voltage Range 0-20 kV
Voltage Resolution 10 V
Voltage Display Digital
Max Current 0.18 mA
Spraybase® Pressure Driven System
Flow Rate Up to 5 bar pressure
Flow Rate Resolution 1 mbar
Flow Rate and Volume Display Digital
Set-up
Emitter to Collector Distance 150mm
XYZ Control G-Code
Melt Head Capcaity 5 g
Dimensions
L X W X H 620mm x 620mm x 600mm
Technical Requirements
Electrical 110-220 V,50-60 Hz
Air Compressed air, 6 mm inlet

Common Polymers used in Melt Electrospinning include:

- Polycaprolactone (PCL)
- Polylactic acid  (PLA)
- Poly(lactide-co-glycolide) (PLGA)
- Polypropylene (PP)
- Polyethylene (PE)
- Poly(methyl methacrylate) (PMMA)


References:

1. Dietmar W. Hutmacher and Paul D. Dalton, (2011) Melt Electrospinning. Chem.Asian J. 6 (1): 44-56

2. Paul D. Dalton et al. (2007) Electrospinning of polymer melts: Phenomenological observations. Polymer, 48: 6823-6833

3. Brown, T. D., Dalton, P. D. and Hutmacher, D. W. (2011), Direct Writing By Way of Melt Electrospinning.Adv. Mater. 23: 5651–5657.

4. Paul D. Dalton et al. (2006) Direct in vitro electrospinning with polymer melts. Biomacromolecules, 7 (3):686-90