Through optimization of simple conventional electrospinning (ES) setup, we overcome many issues posed by conventional ES and produce challenging 3D scaffolds at the human organ scale via a self-switching and self-3D searching process of autopilot single jet ES, with features of excellent shape memory, high porosity and stretchability compared with conventional multi-jets electrospun scaffolds, with these joint merits unattainable by conventional ES and commonly used 3D printing techniques.

Autopilot jet (AJ) is the first to demonstrate 3D scaffold writing, reproducibility, and can replicate patterns from as small as 1 mm to 10s cm, with a writing resolution of a few 100 µm using simple electrospinning (ES) technique. Contrarily, the conventional multi-jets ES allow for only 2D scaffold fabrication with poor writing resolution of centimeters due to random jets bending instabilities. The AJ-spun scaffolds are ~10X porous and mechanically stretchable compared to the latter.

The fiber deposition by autopilot jet (AJ) requires only a basic electrospinning (ES) setup, and is predictable and tunable by field simulation. The robustness and reproducibility of the AJ-3D ES warrants the feasibility of automated 3D ES system as commercial products for academic and industrial R&D customers to make cost-effective and high-profit margin clinically relevant scaffolds for biomedical applications, The tissue engineering market is projected to be worth US$29.64 billion by 2028.