Architecturally defined scaffolds from synthetic collagen and elastin analogues for the fabrication of bioengineered tissues

The microstructure and mechanics of collagen and elastin protein fiber networks dictate the mechanical responses of all soft tissues and related organ systems. In this project, we endeavored to meet or exceed native tissue biomechanical properties through mimicry of these extracellular matrix components with synthetic collagen fiber and a recombinant elastin-like protein polymer. Significantly, this work led to the development of a framework for the design and fabrication of protein-based tissue substitutes with enhanced strength, resilience, anisotropy, and more.;We began with the development of a spinning process for scalable production of synthetic collagen fiber. Fiber with an elliptical cross-section of 53 +/- 14 by 21 +/- 3 mum and an ultimate tensile strength of 90 +/- 19 MPa was continuously produced at 60 meters per hour from an ultrafiltered collagen solution. The starting collagen concentration, flowrate, and needle size could be adjusted to control fiber size. The fiber was characterized with mechanical analysis, micro-differential scanning calorimetry, transmission electron microscopy, second harmonic generation analysis, and subcutaneous murine implant.;We subsequently describe the scalable, semi-automated fabrication of elastin-like protein sheets reinforced with synthetic collagen fibers that can be positioned in a precisely defined three-dimensional hierarchical pattern. Multilamellar, fiber-reinforced elastic protein sheets were constructed with controlled fiber orientation and volume fraction. Structures were analyzed with scanning electron microscopy, transmission electron microscopy, and digital volumetric imaging. The effect of fiber orientation and volume fraction on Young's Modulus, yield stress, ultimate tensile stress, strain-to-failure, and resilience was evaluated in uniaxial tension. Increased fiber volume fraction and alignment with applied deformation significantly increased Young's Modulus, resilience, and yield stress.;Highly extensible, elastic tissues display a functionally important mechanical transition from low to high modulus deformation at a strain dictated by the crimped microstructure of native collagen fiber. We report the fabrication of dense arrays of microcrimped synthetic collagen fiber embedded in elastin-like protein lamellae that mimic this aspect of tissue mechanics. Microcrimped fiber arrays were characterized with scanning electron microscopy, confocal laser scanning microscopy, and uniaxial tension analysis. Crimp wavelength was 143 +/- 5 mum. The degree of crimping was varied from 3.1% to 9.4%, and corresponded to mechanical modulus transitions at 4.6% and 13.3% strain. Up to 1000 cycles of tensile loading did not substantially alter microcrimp morphology.;We designed and prototyped a series of small-diameter vascular grafts consisting of elastin-like protein reinforced with controlled volume fractions and orientations of collagen fiber. A pressure-diameter system was developed and implemented to study the effects of fiber distribution on graft mechanics. The optimal design satisfied target properties with suture retention strength of 173 +/- 4 g-f, burst strength of 1483 +/- 143 mm Hg, and compliance of 5.1 +/- 0.8 %/100 mm Hg.