Abstract

Electrospinning is a relatively simple and promising method for producing polymeric, ceramic, and composite fibers, with diameters ranging from several nanometers to several micrometers. In this study, the influence of PVA solution concentration, tip-to-collector distance, and needle gauge at a constant applied voltage on the morphology and diameter of the electrospun fibers was investigated to optimize conditions for the production of bead-free nanofibers. PVA solutions with concentrations of 5, 7.5, and 10 wt.% were electrospun under varying processing conditions, and the resulting fibers were characterized by SEM. The results demonstrated a strong dependence of fiber morphology on polymer concentration. Low-concentration solutions (5 wt.%) produced fibers with significant bead formation, while increasing the concentration to 10 wt.% resulted in smooth and homogeneous fibers. A non-linear dependence of fiber diameter on tip-to-collector distance was observed, with 140 mm identified as the optimal distance for producing the thinnest fibers. Needle gauge also affected fiber morphology and process stability. The G22 needle produced finer fibers at the optimal collector distance of 140 mm, with the narrowest fiber diameter distribution, indicating the highest uniformity, whereas the G20 and G21 needles exhibited the broader distribution. Statistical analysis (ANOVA) confirmed the significance of the investigated parameters. These findings demonstrate that collector distance and needle gauge should not be evaluated independently and provide practical guidance for optimizing electrospinning conditions for the fabrication of uniform, bead-free PVA nanofibers.

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