Abstract
Anterior cruciate ligament (ACL) injuries are common and often require surgical reconstruction. Autografts remain the clinical standard for ACL reconstruction (ACLR) but are limited by donor site morbidity, inconsistent outcomes, and supply constraints. Here, we report the development of electrospun ligament (ES-Lig), a fully degradable, electrospun scaffold composed of poly(ε-caprolactone) (PCL) designed to mimic the extracellular matrix (ECM) of the native ACL. A scalable manufacturing process was established, incorporating electrospinning, filament stretching, alignment, and braiding. ES-Lig demonstrated controlled in vitro degradation over 12 months while retaining sufficient mechanical strength for early-stage healing. Mechanical characterisation revealed tensile properties and fixation stability comparable to autografts. In vitro biocompatibility was confirmed through cytotoxicity assays, patient-derived ACL explants, and direct cell growth onto the material. In an ovine ACLR model, ES-Lig enabled functional recovery, tissue infiltration throughout its length, and joint stability within 10 weeks post-implantation. Histological and imaging analyses confirmed graft-bone integration, vascularisation, and early ligamentisation. These findings establish ES-Lig as a promising, clinically translatable scaffold for next-generation ACL repair. SUPPLEMENTARY INFORMATION: The online version contains supplementary material available at 10.1007/s42765-025-00632-8.