3D printed multiplexed electrospinning sources for large-scale production of aligned nanofiber mats with small diameter spread

We report the design, fabrication, and characterization of novel, low-cost, and modular miniaturized nanofiber electrospinning sources for the scalable production of non-woven aligned nanofiber mats with low diameter variation. The devices are monolithic arrays of electrospinning emitters made via stereolithography; the emitters are arranged so each element has an independent line of sight to a rotating collector surface. Linear and zigzag emitter packing were evaluated using a PEO solution with the aim of maximizing the throughput of nanofibers with the smallest diameter and narrowest distribution. Current versus flowrate characterization of the devices showed that for a given flowrate a zigzag array produces more current per emitter than a linear array of the same emitter pitch and array size. In addition, the data demonstrate that larger and denser arrays have a net gain in flow rate per unit of active length. Visual inspection of the devices suggests uniform operation in devices with as many as 17 emitters with 300 m inner diameter and 1.5 mm emitter gap. Well-aligned nanofiber mats were collected on a rotating drum and characterized; the 17-emitter device produced the same narrow nanofiber distribution (∼81 nm average diameter, ∼17 nm standard deviation) for all tested flow rates, which is strikingly different to the performance shown by 1-emitter sources where the average fiber diameter significantly increased and the statistics notably widened when the flowrate increases. Therefore, the data demonstrate that massively multiplexing the emitters is a viable approach to greatly increase the throughput of non-woven aligned nanofiber mats without sacrificing the statistics of the nanofibers generated. The production of dry nanofibers by the 17-emitter array is estimated at 33.0 mg min−1 (1.38 mg min−1 per mm of active length), which compares favorably with the reported multiplexed electrospinning arrays with emitters distributed along a line.