The effect of process variables on near-field electrospinning of polycaprolactone studied by response surface methodology

Abstract

Near-field electrospinning (NFES) is a unique method of additive manufacturing (AM) that combines features from conventional electrospinning (CES) and direct ink writing (DIW). NFES allows for the production of nano/micro-scale fibers, similar to CES, while also enabling the creation of fibers and regular structures like DIW. This unique combination sets NFES apart from other AM methods, offering advantages such as low cost, high resolution, compatibility with various materials, and reproducibility. As a result of these properties, NFES has found applications in diverse fields, including tissue engineering, sensors, and electronics. In this study, for a better structural design of the fibrous polycaprolactone construct, the surface response methodology (RSM) was used to study the effect of process variables such as polymer concentration, flow rate, voltage, distance, and collector speed on fiber diameter. The relationship between these parameters and fiber diameter was analyzed. The collector speed was found to have the most influence on fiber diameter, while voltage had the least effect. A statistical model was developed to describe the interactions between these parameters and fiber diameter, validated through experimental tests. The model accurately predicted fiber diameter with less than 16% difference and can be applied to fabricate fibrous constructs by NFES.

Graphical abstract