Core-shell electrospinning combined with sacrificial templating for fabrication of dual-functional porous fibrous scaffolds

Core-shell emulsion electrospinning combined with sacrificial templating shows great promise for constructing multifunctional tissue engineering scaffolds, yet systematic quantitative research on processing-structure-performance relationships remains insufficient. This work presents an integrated fabrication strategy coupling sol-emulsion electrospinning and sacrificial fiber templating to engineer dual-functional porous fibrous scaffolds that achieve synchronized sustained bioactive delivery and efficient cell infiltration. Nerve growth factor (NGF)-loaded core-shell nanofibers were optimized via a water-in-oil emulsion system, and interconnected macroporous networks were introduced by co-electrospinning with polyvinylpyrrolidone (PVP) sacrificial fibers followed by selective water leaching, with pore characteristics flexibly tuned by PVP concentration and flow rate. A triadic correlation model of “wettability-pore structure-mechanical properties” was established to quantify the intrinsic interrelations among processing conditions, scaffold microstructure and overall functional performance. The proposed “Emulsion Dynamic Balance Point” is identified as the critical determinant for fiber morphology, mechanical integrity and controlled release behavior. Under optimal formulation, the core-shell fibers deliver an NGF encapsulation efficiency of 90.0 ± 0.4 %, an ultralow 24-h burst release of 7.1 % and 89.3 % cumulative release over 30 days through a dual-diffusion-barrier mechanism. The scaffold pore size and porosity are tunable in the ranges of 2.88–16.88 μm and 72.3–85.7 %, respectively. The triadic model reveals pore structure as the central governing hub: enlarged porosity enhances capillary-driven topological hydrophilicity but inevitably reduces tensile strength, and a Pareto-optimal formulation balancing cell infiltration capacity and mechanical compatibility is determined. Notably, the macroporous structure does not compromise sustained NGF release kinetics, enabling independent and synergistic tuning of biochemical cues and three-dimensional topological microenvironment.This work provides a low-cost, scalable pathway for controllable manufacturing of multifunctional fibrous biomaterials, and the proposed theoretical framework offers generalizable design principles for advanced regenerative medicine applications.