On-Demand Fabrication of Nanofiber Mats with a Handheld Electrospinning Device for Flexible Postoperative Adhesion Barriers

Abstract Postoperative adhesions remain a major clinical challenge because currently available barrier materials often show limited conformability, insufficient mechanical robustness, and suboptimal performance under moist physiological conditions. Here, we investigated an on-demand strategy for the intraoperative fabrication of antiadhesion barriers using polyurethane dispersion (PUD) and poly(ethylene oxide) (PEO) nanofiber (NF) mats fabricated by a handheld electrospinning device. The physicochemical properties, mechanical performance, degradation behavior, and cytocompatibility of the fabricated NF mats were characterized in vitro. PUD NF mat had superior wet-state mechanical stability, slower degradation, and stronger inhibition of fibroblast migration. Meanwhile, both materials showed favorable cytocompatibility. Antiadhesion efficacy was evaluated in a rat peritoneal ischemic button model, with assessment of gross adhesion formation, histological findings, and immunohistochemical and immunofluorescence markers of α-smooth muscle actin (α-SMA), Ki67, and transforming growth factor-β1 (TGF-β1). In situ electrospun NF mats reduced postoperative adhesion formation relative to controls. PUD showed the greatest reduction in adhesion incidence, tenacity, and histological fibrosis. PUD NF mats demonstrated antiadhesion efficacy comparable to that of Mediclore. The rapid PEO dissolution limited sustained barrier function despite partial macroscopic benefit. A handheld electrospinning device as a portable platform designed for on-demand antiadhesion barrier fabrication was successfully developed. PUD NF mats were identified as a promising candidate for preventing postoperative adhesions.