Recent Advances in Needleless Electrospinning of Ultrathin Fibers: From Academia to Industrial Production

Electrospinning (e-spinning) has been extensively explored as a simple, versatile, and cost-effective method in preparing ultrathin fibers from a wide variety of materials. Electrospun (e-spun) ultrathin fibers are now widely used in tissue scaffold, wound dressing, energy harvesting and storage, environment engineering, catalyst, and textile. However, compared with conventional fiber industry, one major challenge associated with e-spinning technology is its production rate. Over the last decade, compared with conventional needle e-spinning, needleless e-spinning has emerged as the most efficient strategy for large-scale production of ultrathin fibers. For example, rolling cylinder and stationary wire as spinnerets have been commercialized successfully for significantly improving throughput of e-spun fibers. The significant advancements in needleless e-spinning approaches, including spinneret structures, productivity, and fiber quality are reviewed. In addition, some striking examples of innovative device designs toward higher throughput, as well as available industrial-scale equipment and commercial applications in the market are highlighted.