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<p>This review offers a detailed overview of the principles, progress, and uses of electrospinning in materials science. The process, which is based on fundamental physics and chemistry, allows for the production of nanofibers with diameters typically ranging from 10 to 500&#xa0;nm. We discuss various equipment setups and a wide range of materials, including polymers, ceramics, and metals, as well as the integration of bioactive agents, achieving drug loading efficiencies often exceeding 80%. Key factors that control fiber formation such as solution viscosity (100–1,000 cP), applied voltage (10–30&#xa0;kV), and flow rate (0.1–4&#xa0;mL/h) are analyzed for their impact on fiber morphology and material performance. We examine specialized techniques like coaxial, emulsion, and melt electrospinning, along with new apparatus designs. Innovations such as multi-jet and needleless systems have increased production rates from grams per hour to potentially kilograms per hour, greatly improving scalability. The review also explores the structure–property relationships in nanofibers, connecting processing parameters to functional results. Electrospun mats typically exhibit high porosity (often &gt; 90%) and large surface-area-to-volume ratios, making them ideal for applications in tissue engineering, drug delivery, high-efficiency filtration (capturing &gt; 99.9% of airborne particles), and energy storage devices. We highlight emerging trends in multifunctional and responsive fibers. By combining current knowledge, identifying challenges, and suggesting future directions, including integration with technologies like 3D printing, this work serves as a vital resource for both new and experienced researchers aiming to advance electrospinning technology.</p> Graphical abstract <p></p>

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The art and science of electrospinning: a detailed review of process and potential applications

  • 期刊论文

  • 发表日期：

    2025年12月10日

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  • Sanjivani S. Panditkar,
  • Wasudeo B. Gurnule,
  • Prajakta U. Waghe,
  • Parag W. Gurnule,
  • Praveen Kumar

摘要

This review offers a detailed overview of the principles, progress, and uses of electrospinning in materials science. The process, which is based on fundamental physics and chemistry, allows for the production of nanofibers with diameters typically ranging from 10 to 500 nm. We discuss various equipment setups and a wide range of materials, including polymers, ceramics, and metals, as well as the integration of bioactive agents, achieving drug loading efficiencies often exceeding 80%. Key factors that control fiber formation such as solution viscosity (100–1,000 cP), applied voltage (10–30 kV), and flow rate (0.1–4 mL/h) are analyzed for their impact on fiber morphology and material performance. We examine specialized techniques like coaxial, emulsion, and melt electrospinning, along with new apparatus designs. Innovations such as multi-jet and needleless systems have increased production rates from grams per hour to potentially kilograms per hour, greatly improving scalability. The review also explores the structure–property relationships in nanofibers, connecting processing parameters to functional results. Electrospun mats typically exhibit high porosity (often > 90%) and large surface-area-to-volume ratios, making them ideal for applications in tissue engineering, drug delivery, high-efficiency filtration (capturing > 99.9% of airborne particles), and energy storage devices. We highlight emerging trends in multifunctional and responsive fibers. By combining current knowledge, identifying challenges, and suggesting future directions, including integration with technologies like 3D printing, this work serves as a vital resource for both new and experienced researchers aiming to advance electrospinning technology.

Graphical abstract