Biomaterials in the Medical Sector
With an evolving healthcare sector, ageing population and growing incidence of chronic conditions there are opportunities to process biomaterials into advanced fibres and fabrics, including nonwovens and coated substrates for use in medical products. Biomaterials, many with multifunctional properties, play a crucial role in providing diagnostic or therapeutic capabilities in contact with biological tissues and organs, with the ultimate aim of improving patient outcomes.
Advanced drug delivery, scaffolds for tissue regeneration, wound care, stents and other implantable devices are among various fibre and fabric based applications. Modified biomaterial formulations, as well as processing methods, are now being explored to manufacture new medical product formats, suitable for a variety of clinical needs.
The Role of Biomaterials in Fibrous Medical Products
Certain biomaterials have well established compatibility with existing fibre spinning and textile processing methods, while others are incorporated within mixed polymer formations as components for fibres, or coatings. Certain inorganic compounds can be converted into fibres and fabrics directly, or incorporated within fibres as dispersed nanoparticles.
More commonly, natural biopolymers and synthetic polymers are used as materials for making fibres and filaments (alone, or as additives in commixed polymer formulations), fabrics and porous coatings, as follows:
- Polysaccharides: e.g., alginates, cellulose including carboxymethyl cellulose (CMC), regenerated cellulose, chitosan, pectin, hyaluronan and dextrin.
- Polypeptides: e.g., collagen, gelatin, fibrin and various forms of silk.
- Synthetic polymers: e.g., aliphatic polyesters and copolyesters (including PLA, PGA, PLGA, PCL, PHAs and PHBs), polyanhydrides, polyolefins (including PE, HDPE and UHMWPE, PP), PVOH, polyamides, polycarbonates and polyurethanes.
Each material formulation is selected based on physical properties, economics, regulatory requirements and compatibility with the appropriate fibre or textile manufacturing platform with specific medical needs depending on the application.
Challenges and Opportunities in Developing Biomaterials using Textile Processes
Despite the promise of new biomaterials, significant hurdles can be encountered in their development for clinical use. Biomaterials can be challenging to process and manufacture into fibres and fabrics at different scales, often requiring specialist techniques, process modifications and expertise. This can increase development costs and time to market. Meeting regulatory requirements also demands careful planning, good manufacturing practice and validation. Limited infrastructure can be a significant challenge, as many organisations lack the facilities to conduct efficient end-to-end biomaterial development.
Biocompatibility can be investigated in laboratory settings, but the safety and performance for extended periods of time must also be addressed. Careful consideration and materials selection must be employed.
Materials such as alginate and collagen are sensitive to processing conditions such as temperature, pH, and ionic strength, and over-processing can denature proteins, or alter the molecular structure, affecting material functionality and performance.
Controlling moisture levels of highly hydrophilic biomaterials during processing is also challenging, but critical to maintaining their structural integrity and performance in the final application.
Many biopolymers used in medical applications also lack inherent mechanical strength, requiring reinforcement through blending or cross-linking to achieve a balance between flexibility and durability.
Beyond electrospinning to produce nanofibrous webs from polymer solutions or melts, (i.e. products in the form of ‘mats’ and ‘meshes’ and sometimes yarns), developers frequently overlook other highly versatile fibre spinning and fabric forming methods that have the capacity to produce better performing products. This includes wet, dry, dry-wet and gel spinning of biomaterials into continuous filaments, or staple fibres and melt spinning (for thermoplastic polymers). A large variety of fabric forming techniques can then follow, depending on the final products’ required structure-property relationships, and high reproducibility and speed of production are possible. Drylaid, wetlaid and spunlaid nonwovens, followed by appropriate web bonding can enable three-dimensional, porous fabrics to be made very cost effectively from biomaterials than can be challenging to make using other processes.
NIRI can help to address these challenges by providing access to a comprehensive suite of services, including material innovation, pilot-scale fibre and fabric manufacturing, and performance validation, all under one roof.
Innovations in Material Processing
In addition to fibre and fabric manufacturing, textile substrates and the materials from which they are made can also be modified. Functionalisation is a key area of innovation. By modifying biomaterials at the molecular level, as well as at the fibre and fabric levels, it is possible to enhance physical properties and therefore performance, tailoring materials to meet precise clinical needs.
How NIRI Supports Biomaterials Innovation
NIRI provides a holistic approach to the development of fibres, filaments, fabrics, films and coatings containing biomaterials, ensuring a smooth transition from research to market-ready products:
- End-to-End Prototyping: From polymer formulation, fibres, filaments, films and coatings, to fully formed products, NIRI offers comprehensive prototyping capabilities to bring ideas to life quickly and efficiently.
Polymer engineering and compounding.
– Fibre and filament extrusion – melt-spinning (mono and multi-filament), bicomponent spinning, wet-spinning, dry-wet spinning and electrospinning.
– Spunmelt nonwovens – meltblowing and spunbond.
– Staple fibre production, fibre crimping and cutting.
– Drylaid and wetlaid nonwovens, including short (<10 mm) and long staple fibre.
– Web bonding (chemical, mechanical and thermal).
– Coating, laminating, particle incorporation and fabric functionalisation - Analytical Capabilities: We provide performance validation and benchmarking for medical products.
- Customised development: NIRI’s collaborative R&D approach aligns processes with client goals, optimising biomaterial performance for specific applications.
The Future of Biomaterials in Medicine
Developments in biomaterials processing provide an exciting frontier for innovation. In addition to biomaterials formulation, alternative methods of processing biomaterials into finished textile formats, provides a basis to improve diagnostic and therapeutic devices that meet regulatory demands and redefine patient care standards.
NIRI bridges the gap between concept and commercialisation, supporting clients at every stage of the biomaterial development process. From material innovation to commercialisation, we provide the expertise and resources needed to create high-performing, sustainable medical products.
Contact us today to explore how we can help you innovate your medical technologies.