Melt electrospinning: Electrodynamics and spinnability

The high-throughput atomization of polymer solutions for fiber synthesis in a single step aided with corona ionizers

Polymer microfibers are ubiquitous structures across virtually all technological fields. Their applications include, for instance, filter media, tissue regeneration, wound healing and dressing, and reinforcement materials. The most effective methods for fabrication of fibrous micro and nanomaterials rely on electric fields to spin a liquid jet into an ultrafine thread that rapidly dries up forming a fiber. Continuous spinning and collection leads to formation of fiber mats. Here we report a robust yet simple approach for the massive production of liquid threads, which upon acquiring electrical charges in-flight are collected downstream in the form of fibers. The entire process takes place on-line in a single step. The liquid threads are produced through the fragmentation of a polymer solution bulk due to a turbulent interaction of a gas-liquid interface in the interior of an engineered device, a so-called Flow Blurring atomizer. The particularity of this approach consists precisely in such vigorous interaction, at the micrometer scale, which triggers a bubbly motion in the interior of the device, that is a "micro-mixing". Subsequently, the threads are passed through ionized air currents, at ambient conditions, and then stretched to sub-micrometer dimensions by electric fields. Polyvinylpyrrolidone (PVP) as well as carbon nanotubes (CNTs) or graphene oxide sheets (GOSs)-containing PVP fibers, with diameters in the range 100-900 nm, were synthesized via this approach. In the cases studied herein the method was operated at liquid flow rates (i.e. production rates) of 0.2 mL/min but it could be readily increased up to a few tens of mL/min. The method requires further improvement and optimization, nevertheless it is a promising alternative for mass production of polymer fibers.

Review of Design Routines of MXene Materials for Magnesium-Ion Energy Storage Device

Renewable energy storage using electrochemical storage devices is extensively used in various field applications. High-power density supercapacitors and high-energy density rechargeable batteries are some of the most effective devices, while lithium-ion batteries (LIBs) are the most common. Due to the scarcity of Li resources and serious safety concerns during the construction of LIBs, development of safer and cheaper technologies with high performance is warranted. Magnesium is one of the most abundant and replaceable elements on earth, and it is safe as it does not generate dendrite following cycling. However, the lack of suitable electrode materials remains a critical issue in developing electrochemical energy storage devices. 2D MXenes can be used to construct composites with different dimensions, owing to their suitable physicochemical properties and unique magnesium-ion adsorption structure. In this study, the construction strategies of MXene in different dimensions, including its physicochemical properties as an electrode material in magnesium ion energy storage devices are reviewed. Research advancements of MXene and MXene-based composites in various kinds of magnesium-ion storage devices are also analyzed to understand its energy storage mechanisms. Finally, current opportunities, challenges, and future prospects are also briefly discussed to provide crucial information for future research.

Laser-Assisted Melt Electrospinning of Poly(L-lactide-co-ε-caprolactone): Analyses on Processing Behavior and Characteristics of Prepared Fibers

The laser-assisted melt electrospinning (LES) method was utilized for the preparation of poly(L-lactide-co-ε-caprolactone) (PLCL) fibers. During the process, a carbon dioxide laser was irradiated, and voltage was applied to the raw fiber of PLCL. In situ observation of fiber formation behavior revealed that only a single jet was formed from the swelling region under the conditions of low laser power and applied voltage and feeding rate, whereas multiple jets and shots were produced with increases in these parameters. The formation of multiple jets resulted in the preparation of thinner fibers, and under the optimum condition, an average fiber diameter of 0.77 μm and its coefficient of variation of 17% was achieved without the formation of shots. The estimation of tension and stress profiles in the spin-line was also carried out based on the result of in situ observation and the consideration that the forces originated from surface tension, electricity, air friction, and inertia. The higher peak values of tension and stress appearing near the apex of the swelling region corresponded to the formation of thinner fibers for the condition of single-jet ejection. Analyses of the molecular orientation and crystallization of as-spun fibers revealed the formation of a wide variation of higher order structure depending on the spinning conditions.

A U-Shaped Optical Fiber Temperature Sensor Coated with Electrospinning Polyvinyl Alcohol Nanofibers: Simulation and Experiment

This study describes the fabrication of an electrospun, U-shaped optical fiber sensor for temperature measurements. The sensor is based on single mode fibers and was fabricated into a U-shaped optical fiber sensor through flame heating. This study applied electrospinning to coat PVA, a polymer, onto the sensor layer to reduce its sensitivity to humidity. The sensor is used to measure temperature variations ranging from 30 °C to 100 °C. The objectives of this study were to analyze the sensitivity variation of the sensor with different sensor layer thicknesses resulting from different electrospinning durations, as well as to simulate the wavelength signals generated at different electrospinning durations using COMSOL. The results revealed that the maximum wavelength sensitivity, transmission loss sensitivity, and linearity of the sensor were 25 dBm/°C, 70 pm/°C, and 0.956, respectively. Longer electrospinning durations resulted in thicker sensor layers and higher sensor sensitivity, that wavelength sensitivity of the sensor increased by 42%.

Melt electrowriting reinforced composite membrane for controlled drug release

An in-house built hybrid manufacturing device, combining the pros of melt electrowriting (MEW) and melt electrospinning (MES), is firstly proposed to produce a reinforced nonwoven fabric applied in drug delivery systems. MEW is used to print regular PCL lattice, followed by the deposition of a PCL nonwoven fabric loaded with drugs, forming a MEW/MES composite scaffold. Tensile test results suggest that after combining with MEW lattice, the strength of the composite scaffold can have a two-fold improvement and the elongation to break can increase up to 900%. Solvent vapor annealing is applied to adjust drug release rate through controlling the crystallinity of PCL. Although the increased crystallinity restrained drug release, a shish-kebab-shaped fiber structure formed by the annealing facilitates drug release. This MEW-based hybrid printing method can greatly enhance the freedom of making complex scaffold and extend to other nanotechnologies to fabricate reinforced scaffold as well.

Reconstruction of Fibroin Nanofibers (FNFs) via Electrospinning: Fabrication of Poly(vinyl alcohol)/FNFs Composite Nanofibers from Aqueous Solution

Fibroin nanofibers (FNFs) achieved from physical treated silk can keep its original crystal structure, showing excellent mechanical properties, however, processing the FNFs into fibers is still a challenge. Herein, a brand-new environmentally friendly approach is proposed to manufacture FNFs-based composite nanofibers. The water-soluble polymer, poly(vinyl alcohol) PVA, was applied to increase the viscoelasticity of the spinning dope, and the content of FNFs can reach up to 20 wt%. The established phase image of spinning suggested that the concentrations ranging from 6 wt% to 8 wt% are premium to achieving relatively homogenous FNFs/PVA nanofibers. Random fibers were deposited on a fixed collector, while the fiber orientation intensity increased with the rotational speed of drum and started decreasing after 12 m/s. The mechanical properties of the composite nanofibers showed the similar tendency of variation of fiber orientation. In addition, chemical changes, crystallinity, and thermal properties of the composite nanofibers were further clarified by means of FTIR, DSC, and TG. As a result, high FNFs contained nanofibers with excellent thermal properties were created from an aqueous solution. This study is the first original work to realize the spinnability of FNFs, which provides a new insight of the FNFs.

Self-Supporting Three-Dimensional Electrospun Nanofibrous Membrane for Highly Efficient Air Filtration

High-performance air filtration was the key to health protection from biological and ultrafine dust pollution. A self-supporting, three-dimensional (3D) nanofibrous membrane with curled pattern was electrospun for the filtration, of which the micro-fluffy structure displayed high-filtration efficiency and low-pressure drop. The flow field in the 3D filtration membrane was simulated to optimize the process parameters to increase the filtration performance. The qualification factor increased from 0.0274 Pa⁻¹ to 0.0309 Pa⁻¹ by 12.77% after the optimization of the electrospinning parameters. The best filtration efficiency and pressure drop were 93.6% and 89.0 Pa, separately. This work provides a new strategy to fabricate 3D structures through the construction of fiber morphology and promotes further improvement of air filtration performance of fibrous filters.

Polymers for Melt Electrowriting

Melt electrowriting (MEW) is an emerging high-resolution additive manufacturing technique based on the electrohydrodynamic processing of polymers. MEW is predominantly used to fabricate scaffolds for biomedical applications, where the microscale fiber positioning has substantial implications in its macroscopic mechanical properties. This review gives an update on the increasing number of polymers processed via MEW and different commercial sources of the gold standard poly(ε-caprolactone) (PCL). A description of MEW-processed polymers beyond PCL is introduced, including blends and coated fibers to provide specific advantages in biomedical applications. Furthermore, a perspective on printer designs and developments is highlighted, to keep expanding the variety of processable polymers for MEW.

Advances in Functional Polymer Nanofibers: From Spinning Fabrication Techniques to Recent Biomedical Applications

Functional polymeric micro-/nanofibers have emerged as promising materials for the construction of structures potentially useful in biomedical fields. Among all kinds of technologies to produce polymer fibers, spinning methods have gained considerable attention. Herein, we provide a recent review on advances in the design of micro- and nanofibrous platforms via spinning techniques for biomedical applications. Specifically, we emphasize electrospinning, solution blow spinning, centrifugal spinning, and microfluidic spinning approaches. We first introduce the fundamentals of these spinning methods and then highlight the potential biomedical applications of such micro- and nanostructured fibers for drug delivery, tissue engineering, regenerative medicine, disease modeling, and sensing/biosensing. Finally, we outline the current challenges and future perspectives of spinning techniques for the practical applications of polymer fibers in the biomedical field.

Formation of PA12 fibres via melt electrospinning process: parameter analysis and optimisation

Melt electrospinning is a fast-emerging technique for fibre formation. While the process is similar to solution electrospinning, the absence of solvents broadens the applications, avoiding the potential toxicity of solvent residues and enables the usage of non-dissolvable polymers. In this article, the influence of selected melt electrospinning process parameters (tip-to-collector distance, voltage, and melt temperature) on fibre diameter and diameter distribution was investigated. The screening experiments indicated that the lowest fibre diameter median was 2.19 μm. Based on the dependencies between each process parameter and median fibre diameter, the authors used response-surface plots to determine the optimal conditions to produce fibres with the desired fibre diameters. The lowest fibre diameters were obtained with the following process parameter input values: temperature, 348°C; voltage, 19 kV; and tip-to-collector distance, 3 cm. The obtained fibres indicated that the average value of fibre diameter medians decreased in comparison to the screening experiment and the median fibre diameter for the sample “Optim.” was 1.27 μm.

Biomimicry in Bio-Manufacturing: Developments in Melt Electrospinning Writing Technology Towards Hybrid Biomanufacturing

Melt electrospinning writing has been emerged as a promising technique in the field of tissue engineering, with the capability of fabricating controllable and highly ordered complex three-dimensional geometries from a wide range of polymers. This three-dimensional (3D) printing method can be used to fabricate scaffolds biomimicking extracellular matrix of replaced tissue with the required mechanical properties. However, controlled and homogeneous cell attachment on melt electrospun fibers is a challenge. The combination of melt electrospinning writing with other tissue engineering approaches, called hybrid biomanufacturing, has introduced new perspectives and increased its potential applications in tissue engineering. In this review, principles and key parameters, challenges, and opportunities of melt electrospinning writing, and particularly, recent approaches and materials in this field are introduced. Subsequently, hybrid biomanufacturing strategies are presented for improved biological and mechanical properties of the manufactured porous structures. An overview of the possible hybrid setups and applications, future perspective of hybrid processes, guidelines, and opportunities in different areas of tissue/organ engineering are also highlighted.

Melt Electrospinning Designs for Nanofiber Fabrication for Different Applications

Nanofibers have been attracting growing attention owing to their outstanding physicochemical and structural properties as well as diverse and intriguing applications. Electrospinning has been known as a simple, flexible, and multipurpose technique for the fabrication of submicro scale fibers. Throughout the last two decades, numerous investigations have focused on the employment of electrospinning techniques to improve the characteristics of fabricated fibers. This review highlights the state of the art of melt electrospinning and clarifies the major categories based on multitemperature control, gas assist, laser melt, coaxial, and needleless designs. In addition, we represent the effect of melt electrospinning process parameters on the properties of produced fibers. Finally, this review summarizes the challenges and obstacles connected to the melt electrospinning technique.