{"id":173761,"date":"2026-06-24T19:27:00","date_gmt":"2026-06-25T01:27:00","guid":{"rendered":"https:\/\/tecscience.tec.mx\/en\/?post_type=sciencecommunication&p=173761"},"modified":"2026-06-25T04:28:57","modified_gmt":"2026-06-25T10:28:57","slug":"enhanced-nanofibers","status":"publish","type":"sciencecommunication","link":"https:\/\/tecscience.tec.mx\/en\/science-communication\/enhanced-nanofibers\/","title":{"rendered":"A Simple Origami Fold Makes Nanofibers More Precise"},"content":{"rendered":"\n

By\u00a0Hamed Hosseinian<\/a><\/p>\n\n\n\n

Biomedical fibres produced by electrospinning are ultrathin scaffolds for the body: they help regenerate tissue, guide cell growth, and release drugs in a controlled way.<\/p>\n\n\n\n

Yet producing high-quality, aligned nanofibers typically requires specialized equipment, complex setups, and high costs. Their performance depends on one critical factor: how well ordered they are. Achieving that level of control, however, has long been a challenge.<\/p>\n\n\n\n

What if producing highly aligned biomedical fibres didn\u2019t require an expensive kit or elaborate modifications, but merely a simple fold of aluminium guided by smart data analysis?<\/p>\n\n\n\n

The solution is remarkably simple: an aluminum sheet that can be easily attached and removed, requiring no modifications to the electrospinning apparatus.<\/p>\n\n\n\n

It turns out that a folded aluminium sheet, given an origami-like geometry and mounted on a conventional electrospinning drum, achieves something unusual in the field: it yields highly aligned, bead-free polymer fibres without modifying existing lab equipment.<\/p>\n\n\n\n

The study “An origami-based technique for simple, effective and inexpensive fabrication of highly aligned far-field electrospun fibers”<\/em><\/a>\u00a0 combines materials science and machine learning to pinpoint the parameters that truly determine fibre quality. Its clear advantage: it replaces complex arrangements with a practical, scalable and low-cost solution.<\/p>\n\n\n\n

The research shows that improving outcomes often requires better design, not more technology.<\/p>\n\n\n\n

Change the process, not the machine<\/h2>\n\n\n\n

When biomedical fibres are aligned in a single direction, their mechanical properties improve, and they can guide cell growth more effectively. Techniques using parallel electrodes, magnetic fields, specialised collectors, or post-stretching treatments are expensive, often need extra components, limit the collection area, or introduce multi-step processes.<\/p>\n\n\n\n

In shared labs, where equipment must remain versatile, modifying a standard electrospinning system is seldom viable. Rather than changing the machine, the team proposed folding a thin aluminium sheet to create a series of regular creases, which could be placed on a conventional rotating drum collector.<\/p>\n\n\n\n

These folds\u2014inspired by origami\u2014guide fibre deposition and encourage directional alignment without altering the original system.<\/p>\n\n\n\n

This design enables evaluation of when fibres align best and which manufacturing conditions maximise the advantages of an origami-style collector.<\/p>\n\n\n\n

The fibres were made from poly(\u03b5-caprolactone) (PCL), a biodegradable polymer widely used in biomedical applications. The team ran 243 experiments, systematically varying polymer concentration, flow rate, needle-to-collector distance, drum rotation speed, and needle diameter.<\/p>\n\n\n\n

Each sample was analysed by scanning electron microscopy (SEM), fibre diameter measurements, water contact-angle analysis, fast Fourier transform (FFT), and surface intensity mapping.<\/p>\n\n\n\n

One variable stood out clearly<\/p>\n\n\n\n

The Main Driver<\/h2>\n\n\n\n

After demonstrating the origami design\u2019s ability to guide alignment, the next step was to identify which process variables most influenced final material quality.<\/p>\n\n\n\n

Polymer concentration\u2014the material used to form the fibres, here PCL, proved to be the key factor. At 5% solution, no continuous fibres formed, only scattered structures. At 10% and 15%, uniform, bead-free, and markedly better-aligned fibres were obtained.<\/p>\n\n\n\n

Other variables fine-tune the result. Diameters ranged from 1.2 to 1.6 micrometres. Higher flow rates produced thicker fibres, while increasing needle-to-collector distance reduced diameter. Drum speed had little effect on dimension.<\/p>\n\n\n\n

Surface properties changed, too. Fibres remained hydrophobic (115\u00b0\u2013129\u00b0), but higher flow produced denser, more water-repellent mats. A greater distance created more porous structures, allowing better water penetration.<\/p>\n\n\n\n

To assess alignment, the team used fast Fourier transform (FFT), a mathematical tool that reveals orientation patterns in microscopic structures. Disordered fibres produce diffuse signals; aligned fibres yield defined, consistent patterns.<\/p>\n\n\n\n

Surface analyses confirmed that, as conditions were optimised, fibre orientation became more uniform.<\/p>\n\n\n\n

One more step<\/h2>\n\n\n\n

The study\u2019s most innovative aspect is the integration of machine learning.<\/p>\n\n\n\n

Fibres were classified as high quality if they met four criteria: strong alignment, absence of beads, homogenous deposition, and uniform thickness. Only 14.8% of the 243 experiments met all criteria.<\/p>\n\n\n\n

Two interpretable machine-learning models\u2014logistic regression and decision trees\u2014were applied to identify which parameters most strongly predicted high-quality fibres.<\/p>\n\n\n\n

Both models confirmed polymer concentration as the dominant factor, followed by drum rotation speed.<\/p>\n\n\n\n

The logistic regression model correctly predicted high-quality fibres 88% of the time, far above chance.<\/p>\n\n\n\n

Those patterns clarify the mechanism: at low concentration, fibres fail to align; at intermediate concentrations, results improve, but only if the drum spins fast enough. In other words, success requires the right combination of settings, not a single tweak.<\/p>\n\n\n\n

Another key finding concerns the collector itself. The folded aluminium sheet with regular creases prevented bead formation, a defect that degrades fibre quality. The creases act as guides that order deposition without adding anything to the equipment.<\/p>\n\n\n\n

Taken together, the results show that a simple folded-aluminium collector can produce highly aligned, defect-free fibres using a conventional kit. Coupled with machine-learning tools to optimise manufacturing conditions, this approach offers an accessible, low-cost option for labs seeking to develop high-quality biomedical materials<\/p>\n\n\n\n


Main reference<\/h5>\n\n\n\n

Hosseinian, H., Jimenez-Moreno, M., Sher, M. et al.<\/em>An origami-based technique for simple, effective, and inexpensive fabrication of highly aligned far-field electrospun fibers<\/a>. Sci Rep<\/em> 13, 7083 (2023)<\/p>\n\n\n\n

Other references<\/h5>\n\n\n\n
    \n
  1. Cui, C.\u00a0et al.<\/em>\u00a0Optimizing the chitosan-PCL-based membranes with random\/aligned fiber structure for controlled ciprofloxacin delivery and wound healing.\u00a0<\/a>Int. J. Biol. Macromol.<\/em>\u00a0205<\/strong>, 500\u2013510 (2022).<\/li>\n\n\n\n
  2. Dewle, A., Pathak, N., Rakshasmare, P., & Srivastava, A.Multifarious fabrication approaches of producing aligned collagen scaffolds for tissue engineering applications.<\/a>\u00a0ACS Biomater. Sci. Eng.\u00a0<\/em>6<\/strong>(2), 779\u2013797 (2020).<\/li>\n\n\n\n
  3. Cui, C.\u00a0et al.<\/em>\u00a0Electrospun chitosan nanofibers for wound healing application.<\/a>\u00a0Eng. Regen.<\/em>\u00a02<\/strong>, 82\u201390 (2021).<\/li>\n\n\n\n
  4. Zhu, L.\u00a0et al.<\/em>\u00a0Aligned PCL fiber conduits immobilized with nerve growth factor gradients enhance and direct sciatic nerve regeneration<\/a>.\u00a0Adv. Funct. Mater.<\/em>\u00a030<\/strong>(39), 2002610 (2020).<\/li>\n\n\n\n
  5. Wang, L., Chang, M.-W., Ahmad, Z., Zheng, H., & Li, J.-S.\u00a0Mass and controlled fabrication of aligned PVP fibers for matrix-type antibiotic drug delivery systems.<\/a>\u00a0Chem. Eng. J.<\/em>\u00a0307<\/strong>, 661\u2013669 (2017).<\/li>\n\n\n\n
  6. Tindell, R. K., Busselle, L., & Holloway, J.\u00a0Magnetic fields enable precise spatial control of electrospun fiber alignment for fabricating complex gradient materials<\/a>\u00a0(2022).<\/li>\n\n\n\n
  7. Jha, B.\u00a0et al.<\/em>\u00a0Two-pole air gap electrospinning: Fabrication of highly aligned, three-dimensional scaffolds for nerve reconstruction<\/a>.\u00a0Acta Biomater.\u00a0<\/em>7<\/strong>(1), 203\u2013215 (2011).<\/li>\n\n\n\n
  8. Brennan, D. A.\u00a0et al.<\/em>\u00a0Concurrent collection and post-drawing of individual electrospun polymer nanofibers to enhance macromolecular alignment and mechanical properties<\/a>.\u00a0Polymer<\/em>\u00a0103<\/strong>, 243\u2013250 (2016).<\/li>\n\n\n\n
  9. Ghobeira, R.\u00a0et al.<\/em>\u00a0Wide-ranging diameter scale of random and highly aligned PCL fibers electrospun using controlled working parameters<\/a>.\u00a0Polymer<\/em>\u00a0157<\/strong>, 19\u201331 (2018).<\/li>\n<\/ol>\n\n\n\n

    .<\/p>\n\n\n\n

    Author<\/h5>\n\n\n\n

    Hamed Hosseinian<\/a>. Researcher in nanotechnology and bioengineering, specializing in synthetic biology, gene editing, and three-dimensional models for biomedical applications. His work focuses on developing experimental platforms to study complex cellular systems, evaluate therapeutic strategies, and advance scientific and technological innovation. He is a research professor at the Tecnol\u00f3gico de Monterrey School of Engineering and Sciences<\/a>.<\/p>\n\n\n\n

    <\/p>\n","protected":false},"excerpt":{"rendered":"

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