This review examines recent methodologies for fabricating nonwoven polymer materials through electrospinning, focusing on the underlying physical principles, including the effects of external parameters, experimental conditions, material selection, and primary operational mechanisms. Potential applications of electrospun polymer matrices in tissue engineering are analyzed, with particular emphasis on their utility in biomedical contexts. Key challenges in incorporating new materials into biomedical devices are discussed, along with recent advances in electrospinning techniques driving innovation in this field.

Spinal cord injury (SCI) remains a major clinical challenge due to the limited regenerative capacity of the central nervous system (CNS). Effective scaffolds for repair must combine mechanical compatibility with host tissue, controlled degradation matching the time course of regeneration, and microarchitectural features that promote neuronal survival. Electrospun nanofibrous scaffolds mimic the structural and mechanical features of the extracellular matrix, providing critical cues for neuronal adhesion and glial modulation in neural regeneration. Here, we fabricated biodegradable poly(lactic acid)/poly(ε-caprolactone) (PLA/PCL) scaffolds using a dichloromethane/tetrahydrofuran (DCM/THF) solvent system to induce surface porosity via solvent-driven phase separation. The DCM/THF solvent system formulation produced nanofibers with porous surfaces and increased area for cell interaction. PLA/PCL scaffolds showed a Young’s modulus of ~26 MPa and sustained degradation, particularly under oxidative conditions simulating the post-injury microenvironment. In vitro, these scaffolds enhanced neuronal density up to fivefold and maintained ~80% viability over 10 days in primary neuron–glia cultures. Morphometric analysis revealed that DCM/THF-based scaffolds supported astrocytes with preserved process complexity and reduced circularity, indicative of a less reactive morphology. In contrast, scaffolds fabricated with 1,1,1,3,3,3-hexafluoro-2-propanol (HFIP) displayed reduced bioactivity and promoted morphological features associated with astrocyte reactivity, including cell rounding and process retraction. These findings demonstrate that solvent-driven control of scaffold microarchitecture is a powerful strategy to enhance neuronal integration and modulate glial morphology, positioning DCM/THF-processed PLA/PCL scaffolds as a promising platform for CNS tissue engineering.

Flexible implantable electrodes require biocompatibility, mechanical stability, and sufficient electrical conductivity for effective neural interfacing. This work examines ultrasonic treatment during poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) impregnation of electrospun poly(D,L)-lactide (PLA) nonwoven scaffolds as a route to improve filler distribution and functional performance. Four sample types were studied: pristine PLA (untreated and sonicated) and PLA–PEDOT:PSS composites prepared with and without ultrasonication. Scanning electron microscopy shows that ultrasonic treatment suppresses the formation of continuous surface films and promotes homogeneous three-dimensional penetration of PEDOT:PSS throughout the fibrous network. As a result, electrical resistivity decreases by a factor of 7.3, from 294.4 to 40.2 Ω·m. Contact-angle measurements reveal markedly enhanced wettability, with sonicated composites exhibiting rapid water uptake (5–13 s), unlike non-sonicated controls. These findings demonstrate that ultrasound-assisted PEDOT:PSS impregnation yields conductive, highly wettable, and structurally stable scaffolds, highlighting their potential for flexible implantable neural electrodes.

This review examines recent methodologies for fabricating nonwoven polymer materials through electrospinning, focusing on the underlying physical principles, including the effects of external parameters, experimental conditions, material selection, and primary operational mechanisms. Potential applications of electrospun polymer matrices in tissue engineering are analyzed, with particular emphasis on their utility in biomedical context. Key challenges in incorporating new materials into biomedical devices are discussed, along with recent advances in electrospinning techniques driving innovation in this field.