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.
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.