Highly Aligned, Post-Drawn Electrospun Nanofiber Yarns Fabricated via a Parallel-Track System for Suture Materials

Electrospun nanofiber yarns possess desirable biological properties, making them promising candidates for novel suture materials if they can achieve the mechanical performance required for tissue approximation. Nanofibers mimic the size scale of native extracellular matrix proteins, promoting tissue regeneration, favorable immune modulation, and enhanced extracellular matrix production, thereby facilitating improved healing outcomes. They also support cellular adhesion, proliferation, and differentiation, effects that are further enhanced through fiber alignment. Although electrospun yarns have previously been produced using self-bundling techniques, existing methods lack control over fabrication and post-processing parameters, resulting in limited mechanical performance. This study presents a nanoyarn fabrication method that enables controlled alignment and post-drawing to enhance mechanical properties. Nanoyarns produced using this approach were compared with monofilament counterparts and a commercial absorbable suture to evaluate performance as a novel suture material. The method generated uniform nanoyarns with diameter coefficients of variation of 8–30%, consistent with conventional staple yarns. Mechanical testing demonstrated that post-drawing increased Young’s modulus, ultimate tensile strength, and tenacity. Functional testing further showed reduced tissue damage and improved knot stability relative to commercial monofilament sutures. Overall, these findings demonstrate the potential of a parallel-track system to fabricate uniform, aligned, and mechanically suitable nanoyarns for suture applications.