Design and manufacture of an additive manufacturing printer based on 3D melt electrospinning writing of polymer

Abstract Objectives Electrospinning is one of the most well-known approaches to producing polymer nanofibers from a polymer solution by applying a potential difference (voltage) between the spinner and the collector, which is used in various industries such as medicine and military. This method has some significant restrictions, like low process efficiency due to the evaporation of the solvent, remaining solvent on the fibers, which are sometimes toxic, and inability to control the geometry of the produced fibers. On the other hand, preparing some solvents used in the electrospinning of polymer solutions is costly. Polymer melt electrospinning writing is a replacement for this type of electrospinning, which can be mentioned in terms of economy, efficiency, and production of solvent-free fibers. Therefore, in this research, a melt polymer electrospinning device was designed and manufactured according to existing extrusion-based additive manufacturing (AM) devices (3D printer). Methods Changes in an extrusion-based 3D printer to convert it into a writing electrospinning device experimentally. Results PLA and PCL fibers with diameters ranging from 8 to 84 μm were produced. The effect of process variables on the produced fibers’ diameter was investigated: Applied potential difference between the nozzle and the substrate: As its increases, the fiber diameter decreases. Increasing temperature: As its increases, the fiber diameter decreases. Distance between the nozzle and the substrate: As its increases, the fiber diameter increases. Flow rate: As its increases, the fiber diameter increases. Conclusions By presenting a 3D printer-electrospinning device, it is possible to control the fiber’s diameter and the 3D geometry in the 3D printing-electrospinning process.