Background
Electrospinning and additive manufacturing have become increasingly important in fields such as biotechnology, pharmaceuticals, and tissue engineering, where there is growing demand for complex fiber architectures and multifunctional material systems. However, traditional electrospinning methods struggle to meet the precision, scalability, and customization needs of these advanced applications. Creating multi-material, multi-scale structures with embedded bioactive components remains a critical unmet challenge.
Conventional systems are often constrained by multi-step fabrication processes, poor scalability, and limited environmental control. These shortcomings lead to inconsistencies in fiber morphology and material performance, while also restricting the ability to incorporate sensitive or heterogeneous materials. As a result, manufacturers and researchers face barriers when developing high-performance fiber-based products, from tissue scaffolds to smart filtration systems, using current electrospinning platforms.
Technology overview
This technology introduces a next-generation 3D printing electrospinning platform featuring a multi-material printhead (“MAGIC”) capable of producing advanced fiber architectures in a single step. The system incorporates multiple spinnerets powered by independent syringe and pneumatic pumps to simultaneously process different materials. It can generate coaxial, biaxial, and triaxial fibers and embed functional components such as nanoparticles or live cells. Customizable collection components—including XYZ translation stages, spinning rollers, and a six-degree-of-freedom mechanical arm—allow for the direct fabrication of 3D fiber-based structures.
An integrated environmental control chamber maintains precise temperature and humidity levels, and a continuous belt system enables scalable manufacturing. Unlike traditional electrospinning setups, this system combines material diversity, precision control, and high-throughput capability in one platform. The result is a streamlined, highly adaptable process for producing structurally complex and functionally enriched fiber constructs for next-generation applications.
Benefits
- Enables single-step fabrication of coaxial, triaxial, and other advanced fiber morphologies
- Simultaneously processes multiple materials using integrated pneumatic and syringe pump systems
- Supports embedding of functional additives, nanoparticles, or live cells during fiber formation
- Environmental control chamber ensures reproducibility and material integrity
- Scalable, continuous manufacturing enabled by a conveyor belt system and modular collectors
Applications
- Tissue engineering scaffolds
- Controlled-release pharmaceutical dosage forms
- Advanced filtration systems
- Biodegradable fiber-based devices
- Wearable or implantable biomedical materials
Opportunity
- Replaces multi-step electrospinning with a streamlined, scalable, and precise single-step process
- Offers unparalleled flexibility in material design and fiber architecture customization
- Available for licensing to industry partners seeking next-generation electrospinning and fiber fabrication capabilities
