Functional Performance of Electrospun Tissue-Engineered Heart Valve Scaffolds Across Geometries Under Aortic Conditions

Electrospun, bioresorbable polymer scaffolds represent a compelling platform for tissue-engineered heart valves (TEHVs) owing to their fibrous microstructure, tunable mechanics and inherent capacity to support host-cell infiltration and remodeling. While recent in-vitro parametric studies of bioprosthetic heart valve (BHV) geometry have used silicone cast valves and Doppler echocardiography to link design parameters to hemodynamic performance and leaflet strain, the characterization of the functional behavior of electrospun whole-valve TEHV scaffolds across clinically relevant aortic conditions and across distinct leaflet geometries remains limited. Here, we present an end-to-end workflow in which polycaprolactone (PCL) is electrospun directly onto parametrized, 3D-printed mandrels derived from two established analytical leaflet geometry models, yielding 21 whole-valve scaffolds across five geometries without cutting or suturing of flat fiber sheets. Fiber diameter, orientation and scaffold porosity were assessed by scanning electron microscopy and confirmed to be consistent across scaffolds and geometries. A subset of 8 scaffolds were tested in a pulse duplicator under hypotensive, normotensive and hypertensive aortic conditions, achieving a mean geometric orifice area of 44.51% of the total valve area and demonstrating physiological opening and closing behavior throughout. These results emphasize electrospun whole-valve TEHVs as hemodynamically competent constructs at clinically relevant aortic conditions and provide a reproducible, geometry-driven fabrication and evaluation framework to further support their translation toward regenerative heart valve replacement.