Detailed Process Analysis of Biobased Polybutylene Succinate Microfibers Produced by Laboratory-Scale Melt Electrospinning

Melt electrospinning is widely used to manufacture fibers with diameters in the low micrometer range. Such fibers are suitable for many biomedical applications, including sutures, stents and tissue engineering. We investigated the preparation of polybutylene succinate microfibers using a single-nozzle laboratory-scale device, while varying the electric field strength, process throughput, nozzle-to-collector distance and the temperature of the polymer melt. The formation of a Taylor cone followed by continuous fiber deposition was observed for all process parameters, but whipping behavior was enhanced when the electric field strength was increased from 50 to 60 kV. The narrowest fibers (30.05 µm) were produced using the following parameters: electric field strength 60 kV, melt temperature 235 °C, throughput 0.1 mL/min and nozzle-to-collector distance 10 cm. Statistical analysis confirmed that the electric field strength was the most important parameter controlling the average fiber diameter. We therefore report the first production of melt-electrospun polybutylene succinate fibers in the low micrometer range using a laboratory-scale device. This offers an economical and environmentally sustainable alternative to conventional solution electrospinning for the preparation of safe fibers in the micrometer range suitable for biomedical applications.