Tissue Engineering is considered a promising route to address existing deficits of autografts and permanent synthetic prostheses for tendons and ligaments. However, the requirements placed on the scaffold material are manifold and include mechanical, biological and degradation-related aspects. In addition, scalable processes and FDA-approved materials should be applied to ensure the transfer into clinical practice. To accommodate these aspects, this work focuses on the high-scale fabrication of high-strength and highly oriented polycaprolactone (PCL) fibers with adjustable cross-sectional geometry and degradation kinetics applying melt spinning technology. Four different fiber cross-sections were investigated to account for potential functionalization and cell growth guidance. Mechanical properties and crystallinity were studied for a 24-week exposure to phosphate-buffered saline (PBS) at 37 °C. PCL fibers were further processed into scaffolds using multistage circular braiding with three different hierarchical structures. One structure was selected based on its morphology and scaled up in thickness to match the requirements for a human anterior cruciate ligament (ACL) replacement. Applying a broad range of draw ratios (up to DR9.25), high-strength PCL fibers with excellent tensile strength (up to 69 cN/tex) could be readily fabricated. The strength retention after 24 weeks in PBS at 37 °C was 83–93%. The following braiding procedure did not affect the scaffolds’ mechanical properties as long as the number of filaments and the braiding angle remained constant. Up-scaled PCL scaffolds resisted loads of up to 4353.88 ± 37.30 N, whilst matching the stiffness of the human ACL (111–396 N/mm). In conclusion, this work demonstrates the fabrication of highly oriented PCL fibers with excellent mechanical properties. The created fibers represent a promising building block that can be further processed into versatile textile implants for tissue engineering and regenerative medicine.

The structural properties of novel melt-spun polymer optical fibers (POFs) are investigated by small-angle X-ray scattering. The amorphous PMMA POFs were subjected to a rapid cooling in a water quench right after extrusion in order to obtain a radial refractive index profile. Four fiber samples were investigated with small-angle X-ray scattering (SAXS). The resulting distance-distribution functions obtained from the respective equatorial and meridional SAXS data exhibit a real-space correlation peak indicative of periodic cross-sectional and axial variations in the scattering density contrast. Simple model calculations demonstrate how the structural information contained particularly in the equatorial distance distribution function can be interpreted. The respective results are qualitatively verified for one of the fiber samples by comparison of the model curve with the measured SAXS data. Eventually, the study confirms that the cross-sectional variation of the (scattering-) density is the main reason for the formation of radial refractive-index profiles in the POFs.

Designing hollow fiber (HF) membrane modules occupies one of the key positions in the development of efficient membrane processes for various purposes. In developing HF membrane modules, it is very important to have a uniform HF distribution and flow mixing in the shell side to significantly improve mass transfer and efficiency. This work suggests the application of different textile 3D HF structures (braided hoses and woven tape fabrics). The 3D structures consist of melt-spun, dense HFs based on poly(4-methyl-1-pentene) (PMP). Since the textile processing of HFs can damage the wall of the fiber or close the fiber bore, the membrane properties of the obtained structures are tested with a CO₂/CH₄ mixture in the temperature range of 0 to 40 °C. It is shown that HFs within the textile structure keep the same transport and separation characteristics compared to initial HFs. The mechanical properties of the PMP-based HFs allow their use in typical textile processes for the production of various membrane structures, even at a larger scale. PMP-based membranes can find application in separation processes, where other polymeric membranes are not stable. For example, they can be used for the separation of hydrocarbons or gas mixtures with volatile organic compounds.

The structural properties, mainly the spatial variation of density and chain interaction, of melt-spun polymer optical fibres (POFs) are investigated by small-angle X-ray scattering (SAXS) and compared to Monte-Carlo polymer simulations. The amorphous PMMA POFs had been subjected to a rapid cooling in a water quench right after extrusion in order to obtain a radial refractive-index profile. Four fibre samples with different processing parameters are investigated and the SAXS data analysed via Guinier approach. Distance-distribution functions from the respective equatorial and meridional SAXS data are computed to extract the fibres’ nanostructures in the equatorial plane and along the fibre axis, respectively. Temperature profiles of the cooling process are simulated for different locations within the fibre and taken as input for Monte-Carlo simulations of the polymer structure. The simulation results agree with the SAXS measurements in terms of the cooling profile’s strong influence on the structural properties of the fibre: slower cooling in the centre of the fibre leads to stronger interchain interaction, but also results in a higher density and more homogenous materials with less optical scattering.

We present a model for a Monte-Carlo simulation of polymer optical fiber fabrication based on a novel method using heat treatment after melt spinning. The polymer is modeled using three-dimensional bond-fluctuation with the Leonard-Johns potential for non-bonded interactions of different polymers alongside the bond, bend and torsion potential for the bonded interactions within the same polymer. The studied fabrication parameters were different cooling rates, pressure and the polymer chain length. Their influence is investigated on properties such as the radius of gyration R_G, physical and optical density ρ and n, and the isothermal compressibility, which will be affected e.g. by the phase-transition temperature T_g. They influence both mechanical and optical properties of the produced fiber.