Researchers have drawn inspiration from the silkworm cocoon to refine how synthetic fibers are made, a development highlighted by the American Chemical Society. By studying how a caterpillar stretches a solution of two proteins into a fine thread, engineers gained fresh ideas for producing man-made fibers with greater precision and efficiency.
The natural process involves a caterpillar drawing a protein solution through a spinning system to form a cohesive filament. Translating this into a lab setting demands advanced equipment and careful control; otherwise, the fibers can become uneven or clumpy. The team explored natural strategies to improve consistency and quality, aiming to simplify the production pathway without compromising performance.
In one setup, the researchers placed a piece of styrofoam soaked in a solution of polyethylene oxide and inserted multiple microneedles into it, then released the fluid to form filaments. The movement was tuned to mimic the caterpillar’s technique: drawing fibers in a straight line to produce smooth, uniform strands, linking many fine fibers together, and finally twisting the bundle to create a single, strong yarn. In an alternative version, the design removed the needles entirely, letting the rough surface of the foam serve as the contact points to guide fiber formation.
As part of an exploratory test, the scientists stretched the resulting strings and applied them directly to human skin to fashion a custom bandage. The bandage fibers carried an antibiotic component that successfully inhibited bacterial growth, demonstrating a potential dual function for future medical materials.
The researchers envision broad applications for this technology. Beyond medical materials, the approach could enable the production of versatile fibers for textiles, wound care, and other practical uses, aiming to streamline manufacturing while maintaining high fiber performance and safety standards (ACS).