Fabrication of 3D Hemispherical PCL-Based Scaffolds Through Far-Field Electrospinning Method for Their Potential Use as Contact Lenses

Maintaining precise control over fiber alignment during the electrospinning process is a significant challenge in material science. Various techniques have been explored to enhance fiber alignment, including the use of rotating collectors, patterned electrodes, and magnetic fields. However, these methods are typically complex, expensive, and involve multiple procedural steps, which can hinder their practical application in industrial settings. In this work, polycaprolactone (PCL) was used to electrospun scaffolds characterized by meshed, aligned, and grid fiber structures. A cost-effective approach for fabricating grid fibers, offering enhanced control over the scaffold, and potentially beneficial for medical applications was developed in this study. Using previously fabricated aligned fibers served as a foundation for developing ocular contact lenses incorporating the newly designed grid and meshed fibers. A comparative proof-of-concept study was conducted, utilizing three distinct fiber orientations to evaluate the efficacy and potential use in ocular drug delivery of each fiber type within the scaffolds. The morphology, light transmittance, mechanical properties, and wettability of the contact lenses were systematically assessed. The PCL-based ocular contact lenses, specifically tailored to conform to the anatomical shape of the eye, demonstrated a significant extension in Rhodamine B residence time, achieving an increase of up to two hours compared to conventional eye drops on the porcine cornea. Among the fiber types analyzed, grid fibers emerged as the most promising, followed by aligned fibers, both exhibiting superior Rhodamine B retention compared to meshed fibers. In conclusion, the innovative advancements in fiber alignment techniques and the use of PCL in the fabrication of ocular contact lenses underscore the potential for enhanced medical applications.