Electrohydrodynamic Printing of Microfibrous Architectures with Cell‐Scale Spacing for Improved Cellular Migration and Neurite Outgrowth

Abstract Electrohydrodynamic (EHD) printing provides unparalleled opportunities in fabricating microfibrous architectures to direct cellular orientation. However, it faces great challenges in depositing orderly microfibers with cell‐scale spacing due to inherent fiber–fiber electrostatic interactions. Here a finite element method is established to analyze the electrostatic forces induced on the EHD‐printed microfibers and the relationship between the fiber diameter and spacing for parallel deposition of EHD‐printed microfibers is revealed theoretically and experimentally. It is found that uniform fiber arrangement can be achieved when the fiber spacing is five times larger than the fiber diameter. This finding enables the successful printing of parallel fibrous architectures with a fiber diameter of 4.9 ± 0.1 µm and a cell‐scale fiber spacing of 25.6 ± 1.9 µm. The resultant microfibrous architectures exhibit unique capability to direct cellular alignment and enhance cellular density and migration as the fiber spacing decreases from 100 to 25 µm. The EHD‐printed parallel microfibers with cell‐scale spacing are found to improve the outgrowth length of neurites and accelerate the migration of Schwann cells from Dorsal Root Ganglion spheres, which facilitate the formation of densely‐arranged and highly‐aligned cellular constructs. The presented method is promising to produce biomimetic microfibrous architectures for functional nerve regeneration.