A Novel Approach to Up-Scaled Open-Surface Electrospinning

Scaling nanofiber production beyond the limits of traditional needle-based systems.

Electrospinning remains the most widely used and versatile technique for nanofiber production at the laboratory scale. However, one of the key challenges in recent years has been the development of electrospinning systems capable of significantly increasing nanofiber membrane production capacity. To address this limitation, scalable electrospinning architectures such as needle-based (nozzle) and needle-less (open-surface) systems have been introduced.

In this study, the performance and scalability of both approaches are investigated through the electrospinning of five diverse polymers—PVA, PVDF, TPU, PA 6, and PHB—using needle-based and open-surface electrospinning configurations. The results highlight the strengths, limitations, and throughput differences between these two methods, providing valuable insights for industrial-scale nanofiber membrane manufacturing. Open-surface electrospinning, in particular, demonstrates strong potential as a next-generation solution for high-output nanofiber production.