Periodic Reporting for period 1 - ArtSilkTex (Artifical spider silk textiles)
Período documentado: 2022-09-01 hasta 2024-02-29
A biobased economy is a prerequisite for the transition into a sustainable society. An important part of this transition is the development of novel, biobased materials that can be produced in a sustainable way using renewable resources. However, we are still heavily dependent on materials made from fossil raw materials, especially when it comes to high-performance fibers. A potentially very interesting material in this context is spider silk, Nature’s toughest fiber. Spider silk is attractive for use as e.g. textiles, reinforcement in composite construction materials and as implants for applications in regenerative medicine. However, production and spinning of artificial spider silk fibers have shown to be very challenging, and current methods to produce silk fibers use harsh solvents and denaturing conditions. These methods not only are harmful to the environment but also prevent the silk proteins from assembling into fibers in the same complex way that native silk proteins do.
We have recently made marked progress in establishing a sustainable and scalable process for making artificial spider silk: 1) we have developed a process for spinning biomimetic artificial spider silk fibers (using water as the sole solvent); 2) by using a protein engineering approach, we have markedly increased the mechanical properties of the fibers, which now approach those of the native fiber; and 3) we have developed a process that results in unprecedented levels of recombinant silk proteins by using a bioreactor. From the protein extracted from a 1-liter bacterial culture, we can extract enough protein to spin an 80km long fiber. Hence, we can now, for the first time, produce continuous artificial spider silk fibers in a process that is devoid of organic solvents and at a scale and cost that is compatible with industrial applications. The overall objective of ArtSilkTex was therefore to show that we can spin multifilament fibers that can be used to make yarns, protect IP, and establish a route to commercialization.
We have recently made marked progress in establishing a sustainable and scalable process for making artificial spider silk: 1) we have developed a process for spinning biomimetic artificial spider silk fibers (using water as the sole solvent); 2) by using a protein engineering approach, we have markedly increased the mechanical properties of the fibers, which now approach those of the native fiber; and 3) we have developed a process that results in unprecedented levels of recombinant silk proteins by using a bioreactor. From the protein extracted from a 1-liter bacterial culture, we can extract enough protein to spin an 80km long fiber. Hence, we can now, for the first time, produce continuous artificial spider silk fibers in a process that is devoid of organic solvents and at a scale and cost that is compatible with industrial applications. The overall objective of ArtSilkTex was therefore to show that we can spin multifilament fibers that can be used to make yarns, protect IP, and establish a route to commercialization.
We have established a freedom-to-operate analysis as well as a patent strategy. This report showed that although there are several granted patents that concern the production and spinning of recombinant spidroins, our patent applications cover unique features of both the recombinant proteins and the spinning method. During the project, we have compiled a novel patent application and identified a revolutionary production method that is believed to cut the costs for production by 90%. This invention is currently backed up by experimental evidence and a patent application will be submitted shortly. With the help of SLU Holding and the fashion industry, we have prepared for the launch of a spin-off company.
The grant allowed us to acquire a multifilament wet spinner with multiple baths, a drying line, a post-spin-stretch device, and a winder. By using this machine, we have been able to spin multifilament artificial spider silk fibers using solely aqueous solutions for the first time. By screening different spinning conditions, we could identify important parameters in the process and establish a protocol for stable fiber spinning. During the project, we produced 6kg of spider silk proteins, which is six times more than we anticipated, and managed to spin ca 500g of multifilament fibers from a part of this production batch. These fibers are currently being processed into yarns for subsequent benchmarking against established materials.
For business development, we have had support from SLU Holding and an international company in fashion. We have established a clear path to commercialization and connections to several key end users. As evidence of the quality of our work and because of the huge potential of our fibers, the international fashion company has supported the development by acquiring laboratory equipment that is now installed in our lab.
The grant allowed us to acquire a multifilament wet spinner with multiple baths, a drying line, a post-spin-stretch device, and a winder. By using this machine, we have been able to spin multifilament artificial spider silk fibers using solely aqueous solutions for the first time. By screening different spinning conditions, we could identify important parameters in the process and establish a protocol for stable fiber spinning. During the project, we produced 6kg of spider silk proteins, which is six times more than we anticipated, and managed to spin ca 500g of multifilament fibers from a part of this production batch. These fibers are currently being processed into yarns for subsequent benchmarking against established materials.
For business development, we have had support from SLU Holding and an international company in fashion. We have established a clear path to commercialization and connections to several key end users. As evidence of the quality of our work and because of the huge potential of our fibers, the international fashion company has supported the development by acquiring laboratory equipment that is now installed in our lab.
In ArtSilkTex we have shown that large-scale production of silk proteins is economically feasible, and importantly, invented a very efficient production method that goes far beyond the state of the arts (to be patented). Furthermore, we have pioneered the spinning of artificial silk fibers in a multifilament wet-spinner, using only water-based solution and ambient conditions, and successfully generated 500g of fibers.
Figure description:
Multifilament spinner: Features the multimodal multifilament wet-spinner that is installed in our lab. The pump, located on the left (not visible), was used to extrude the concentrated sider silk protein solution into a spinning bath with an observation window. The wet spinner is also equipped with two washing lines, a drying line, and bobbins for fiber collection.
Multifilament spinning: A photo taken through the observation window as multifilament artificial spider silk is being spun using a slightly acidic aqueous solution at ambient temperatures, without the need for toxic or harsh chemicals.
Multifilament fiber collection: Collection of the multifilaments on a bobbin.
Figure description:
Multifilament spinner: Features the multimodal multifilament wet-spinner that is installed in our lab. The pump, located on the left (not visible), was used to extrude the concentrated sider silk protein solution into a spinning bath with an observation window. The wet spinner is also equipped with two washing lines, a drying line, and bobbins for fiber collection.
Multifilament spinning: A photo taken through the observation window as multifilament artificial spider silk is being spun using a slightly acidic aqueous solution at ambient temperatures, without the need for toxic or harsh chemicals.
Multifilament fiber collection: Collection of the multifilaments on a bobbin.