Electrospinning method

What is the electrospinning process?

The electrospinning process is a nanofiber production process that  applies a high-voltage electric field to a polymer solution or melt. This field induces the formation of a charged jet that elongates and solidifies into ultra-fine fibers. These fibers are randomly deposited onto a collector, forming a highly porous mat with a surface area-to-volume ratio ideal for cell adhesion and scaffold formation.

Electrospinning enables the creation of tailored microstructures with controlled porosity, fiber diameter, and alignment—critical parameters for biomedical engineering and tissue regeneration. The process is simple yet versatile, enabling as well the encapsulation of active components and the creation of multifunctional, multilayer materials.

Components of electrospinning

An electrospinning setup at Applus+ Laboratories typically includes:

• Polymer feed system: Syringe or reservoir containing the polymer solution.
• High-voltage power supply: Generates the electric field required for jet formation.
• Spinneret (needle or nozzle): Initiates the polymer jet.
• Collector (flat plate or rotating drum): Captures the nanofibers and defines the mat geometry.

Environmental controls such as temperature and humidity are integrated to ensure reproducibility and material consistency.

How does electrospinning works? 

Electrospinning works by leveraging electrostatic forces to stretch a polymer solution into continuous nanofibers. As the polymer exits the spinneret, the electric field causes the jet to whip and elongate, reducing its diameter. Solvent evaporation or thermal solidification stabilizes the fibers, which are then deposited onto a grounded collector.

Key influencing parameters include:

• Solution properties (polymer type, concentration, solvent)
• Process parameters (voltage, flow rate, collector speed)
• Environmental conditions (temperature, humidity)

Fiber orientation and morphology can be controlled by adjusting collector speed and environmental factors, enabling randomly distributed or highly oriented fibers, as well as complex structures such as core-shell and hollow nanofibers.

This process allows Applus+ Laboratories to produce scaffolds with:

• High porosity (>90%)
• Interconnected pore networks
• Tunable mechanical properties
• Biocompatibility for medical use

Polymers used in electrospinning

Applus+ Laboratories utilizes a wide range of polymers in electrospinning, including:

• Resorbable polymers: e.g., polylactic acid (PLA), polycaprolactone (PCL)
• Synthetic and non-resorbable polymers: e.g., polyurethane, PVDF, polyethylene oxide (PEO)
• Natural polymers: silk fibroin, chitosan
• Multimaterial blends/layer: for enhanced mechanical or biological performance

These materials are selected based on application-specific requirements such as degradation rate, mechanical strength, and regulatory compliance.

What are the advantages of the electrospinning method?

Electrospinning offers several advantages for advanced material development:

• Precision control over fiber morphology and scaffold architecture
• High surface area for improved cell interaction and drug delivery
• Versatility in polymer selection and functionalization
• Scaffold mimicry of extracellular matrix for tissue engineering
• Scalable production for medical devices and industrial applications
• High porosity and permeability for filtration and energy applications
• Ability to encapsulate active components for controlled release

Success stories

Healthcare Sector:

• Smart medical device for bone reconstruction (SBR project): Encapsulation of active species by liposomes in core-shell fibers and assembly of 3D scaffold/electrospun patch.
• Innovative biomaterial for skin equivalent (TISSYOU project)with Two-layer system with controlled porosity and mechanical properties.

Energy:

• Electrospun separators for batteries, proton exchange membranes for fuel cells.

Our expertise includes:

• Process optimization: Impact of process parameters and sterilization on degradation kinetics; adhesion between layers; reproducibility; implementation over large areas.
• Characterization: Adhesion, SEM, permeability, mechanical testing.
• Competences: Surface and integrated functionalization, tuning of mechanical properties and porosity, optimization of release kinetics and degradation for medical applications.

At Applus+ Laboratories, electrospinning is integrated into R&D workflows to support innovation in implantable devices, wound healing matrices, and bioactive coatings. We are committed to innovation and co-development, pushing the boundaries of electrospinning for new applications in healthcare, energy, and environmental technologies.