A theoretical analysis and prediction of pore size and pore size distribution in electrospun multilayer nanofibrous materials

Electrospinning process can fabricate nanomaterials with unique nanostructures for potential biomedical and environmental applications. However, the prediction and, consequently, the control of the porous structure of these materials has been impractical due to the complexity of the electrospinning process. In this research, a theoretical model for characterizing the porous structure of the electrospun nanofibrous network has been developed by combining the stochastic and stereological probability approaches. From consideration of number of fiber‐to‐fiber contacts in an electrospun nanofibrous assembly, geometrical and statistical theory relating morphological and structural parameters of the network to the characteristic dimensions of interfibers pores is provided. It has been shown that these properties are strongly influenced by the fiber diameter, porosity, and thickness of assembly. It is also demonstrated that at a given network porosity, increasing fiber diameter and thickness of the network reduces the characteristic dimensions of pores. It is also discussed that the role of fiber diameter and number of the layer in the assembly is dominant in controlling the pore size distribution of the networks. The theory has been validated experimentally and results compared with the existing theory to predict the pore size distribution of nanofiber mats. It is believed that the presented theory for estimation of pore size distribution is more realistic and useful for further studies of multilayer random nanofibrous assemblies. © 2013 Wiley Periodicals, Inc. J Biomed Mater Res Part A, 2013.