Aqueous-based spinning of fibers from self-assembling structural proteins.

There has been long-standing interest in generating fibers from structural proteins and a great deal of work has been done in attempting to mimic dragline spider silk. Dragline silk balances stiffness, strength, extensibility, and high energy to break. Mimicking these properties through aqueous-based spinning of recombinant silk protein is a significant challenge; however, an approach has been developed that facilitates the formation of fibers approaching the mechanical properties seen with natural dragline silk. Due to the multitude of solution, spinning and post-spinning variables one has to consider, the method entails a multivariate approach to protein solution processing and fiber spinning. Optimization to maximize mechanical integrity of the fibers is performed by correlating the solution and spinning variables to mechanical properties and using this information for subsequent fiber spinning studies. Here, the method is described in detail and emphasizes the lessons learned during the iterative variable analysis process, which can be used as a basis for aqueous-based fiber spinning of other structural proteins.

Spider silk fibers spun from soluble recombinant silk produced in mammalian cells.

Spider silks are protein-based "biopolymer" filaments or threads secreted by specialized epithelial cells as concentrated soluble precursors of highly repetitive primary sequences. Spider dragline silk is a flexible, lightweight fiber of extraordinary strength and toughness comparable to that of synthetic high-performance fibers. We sought to "biomimic" the process of spider silk production by expressing in mammalian cells the dragline silk genes (ADF-3/MaSpII and MaSpI) of two spider species. We produced soluble recombinant (rc)-dragline silk proteins with molecular masses of 60 to 140 kilodaltons. We demonstrated the wet spinning of silk monofilaments spun from a concentrated aqueous solution of soluble rc-spider silk protein (ADF-3; 60 kilodaltons) under modest shear and coagulation conditions. The spun fibers were water insoluble with a fine diameter (10 to 40 micrometers) and exhibited toughness and modulus values comparable to those of native dragline silks but with lower tenacity. Dope solutions with rc-silk protein concentrations >20% and postspinning draw were necessary to achieve improved mechanical properties of the spun fibers. Fiber properties correlated with finer fiber diameter and increased birefringence.