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Polypropylene (PP) based hernia mesh often shows multiple post‐surgery complications due to lack of biocompatibility, poor cell attachment, and unwanted tissue adhesion. These limitations can be addressed by material designing and surface modification of a mesh with side‐specific properties such as the visceral side (facing intestine) with low protein and cell attachment and the parietal side (facing incision) with improved cell attachment properties for normal healing. However, the development of dual‐sided mesh is very challenging because of its porous structure. Herein, a dual‐sided biocompatible mesh with protein anti‐adsorption and cell attachment properties on two different sides is developed by grafting highly hydrophilic 2‐methcryloyloxyethyl phosphorylcholine polymer (PMPC) on the plasma‐activated visceral side, while the parietal side is coated with bioactive chitosan and functionalized nanodiamond (Chi/FND) using a temporary polyvinyl alcohol (PVA) mold. The PMPC‐grafted side demonstrated excellent resistance to protein adsorption (96% reduction compared to PP) and cell attachment. However, the bioactive coating on the parietal side has significantly improved cell attachment and proliferation properties. In addition, both sides confirmed the presence of the respective biomaterials after an accelerated degradation study for 28 days. Hence, the newly developed dual‐sided mesh by semi‐solid polymer mold (SSPM) method is a promising candidate to address the long‐existing multiple issues of hernia mesh. [ABSTRACT FROM AUTHOR]

Commercial hernia mesh is commonly made from polypropylene (PP), due to its inertness, biocompatibility, physical properties, ease of processing and versatility for conversion into flexible shape. However, reportedly hernia mesh prepared from PP experienced issues such as diminished long-term strength, foreign body rejection, lack of biocompatibility and high adhesion to the abdomen wall. Infiltration of the mesh by soft tissue (called remodeling) results in an integration of mesh into the body, leading to a rapid reduction in mesh mechanical properties and potential infection. Here, this study addresses these issues through the incorporation of nanodiamond (ND) into PP filament and coating on the surface of plasma-treated PP-ND mesh. The results show that the dynamic modulus of the PP-ND mesh increased significantly, without compromising its flexibility. Coating PP-ND mesh with hydroxylated ND led to a reduction in nonspecific protein adsorption onto the surface of nanocomposite, which is an important characteristic for hernia mesh to prevent foreign body reaction, attachment of mesh to the abdominal wall and nearby organs. In-vitro study with mammalian cells shows that coated PP-ND mesh with functionalized ND exhibits a significant increase in the number of adhered cells with more elongated morphology in comparison with other PP meshes, due to the better hydrophilicity. Therefore, the ND coated nanocomposite mesh can be a promising candidate for hernia repair in the future; however, more investigation is required. Unlabelled Image • Developed Polypropylene–nanodiamond (PP-ND) composite hernia mesh developed is the first reported in the literature. PP-ND provided exceptional long-term stability performance, mechanical and biological properties. • Plasma treated PP-ND mesh supported attachment of hydroxylated ND to the surface resulting in a durable ND coating. • PP-ND exhibited excellent stability and performance properties, that lead to a durable and biocompatible implanted mesh • PP-ND exhibited significant reduction in protein absorption consistent with lower inflammatory responses • No cytotoxicity was observed that indicated PP-ND scaffold could be ideal for complex hernia repair management. [ABSTRACT FROM AUTHOR]