Scalable Manufacture and Cutting-Edge Applications of Electrospun Nanofibrous Assemblies

Abstract

Electrospinning has emerged as an important platform for manufacturing nanofibrous assemblies with high specific surface area, tunable porosity, and versatile functionalizability, making it highly attractive for advanced fiber-based materials. However, bridging the gap between laboratory-scale studies and industrial-scale production requires not only scalable manufacturing strategies, but also rational structural design of electrospun assemblies. In this review, the fundamental mechanisms of electrospun nanofiber formation are summarized, with particular emphasis on jet dynamics, multi-jet interference, and free-surface jet initiation, which together provide the mechanistic basis for scalable production. The evolution of scalable electrospinning technologies, with a particular focus on spinneret design innovations in both multi-nozzle and free-surface systems, is then critically reviewed. Building on this manufacturing perspective, the structural engineering of electrospun assemblies is further discussed, highlighting the progression from two-dimensional (2D) electrospun nanofibrous membranes to one-dimensional (1D) core-spun yarns and multi-scale fiber composite yarns. Representative applications in functional and smart textiles are then discussed. Finally, the major challenges associated with industrialization, structural stability, and device integration are outlined, together with future opportunities for scalable, multifunctional, and more sustainable electrospun materials.

Graphical Abstract

Keywords

Electrospinning / Scalable manufacture / Electrospun nanofibrous membranes / One-dimensional fibrous assemblies / Advanced applications

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Funding

National Natural Science Foundation of China(52373032)

RIGHTS & PERMISSIONS

Donghua University, Shanghai, China

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