Electrospinning Enables Opportunity for Green and Effective Antibacterial Coatings of Medical Devices

Abstract

The growing antimicrobial resistance and the increasing environmental concerns associated with conventional antibacterial agents have prompted a search for more effective and sustainable alternatives. Biopolymer-based nanofibers are promising candidates to produce environment-friendly antibacterial coatings, owing to their high surface-to-volume ratio, structural adaptability, and tunable porosity. These features make them particularly well-suited for delivering antimicrobial agents in a controlled manner and for physically modifying the surface of medical devices. This review critically explores recent advances in the use of electrospun fibers enhanced with natural antimicrobial agents as eco-friendly surface coatings. The mechanisms of antibacterial action, key factors affecting their efficacy, and comparisons with conventional antibacterial agents are discussed herein. Emphasis is placed on the role of a "green electrospinning" process, which utilizes bio-based materials and nontoxic solvents, to enable coatings able to better combat antibiotic-resistant pathogens. Applications in various clinical settings, including implants, wound dressings, surgical textiles, and urinary devices, are explored. Finally, the environmental benefits and prospects for the scalability and sustainability of green coatings are discussed to underscore their relevance to next-generation, sustainable solutions in healthcare.

Keywords: antimicrobial resistance; biopolymer; eco-friendly; nanofiber; natural antimicrobial agents; sustainable healthcare.

Figure 3

Examples of biomedical applications of antibacterial fiber coatings: (A) FE-SEM images of a multifunctional wound dressing fabricated by coating commercial cotton gauze with CS, ZnO nanopowder, and electrospun PCL fibers loaded with antibiotics. This composite structure enhances antibacterial activity and promotes wound healing; adapted from Ref. [162]. (B) Schematic of a dual-layer cotton-based wound dressing coated with PVA-CS electrospun fibers incorporating Agrimonia eupatoria L. extract. The bilayer configuration combines the structural support of cotton with the bioactivity of herbal-loaded electrospun fibers for advanced wound care; adapted from Ref. [168]. (C) Bi-layered electrospun fibers of PCL and PLGA applied to titanium implants for sustained co-delivery of rifampicin and vancomycin. This approach provides durable implant coatings that effectively prevent both early and delayed implant-associated infections; adapted from Ref. [174]. (D) Vancomycin-loaded collagen/hydroxyapatite (COLHA+V) fiber layers electrospun onto 3D-printed titanium implants. This coating prevented S. epidermidis-induced bone damage and improved osseointegration; adapted from Ref. [175]. (E) Schematic of a 3-layer biodegradable face mask incorporating needleless electrospun phytochemical-loaded fibers to combat viral transmission during the COVID-19 pandemic. The design includes a protective top layer, an active electrospun fiber middle layer, and a soft inner layer for comfort; adapted from Ref. [170].

Figure 1

Schematic representation of a typical ES setup composed of a high-voltage power supply, a syringe pump, a spinneret (needle), and a grounded collector. The figure includes representative scanning electron microscopy (SEM) micrographs of diverse electrospun fibers reproduced. Adapted from Ref. [39].

Figure 2

Bacterial cellulose (BC) ES in IL: (A) schematic the ES setup including a coagulation bath to remove IL; (B) photograph of the setup; (C,D) representative scanning electron microscopy (SEM) micrographs of BC fibers obtained using either (C) DMSO or (D) GVL as a co-solvent of BmimAc. Adapted from Ref. [100].

Figure 4

Sustainable approaches in green ES: polymers, solvents, additives, and energy reduction strategies (created by the authors).