Development of Self‐Healing Nanofiber‐Reinforced Green Composites via Dual‐Nozzle Coaxial Electrospinning for Enhanced Mechanical Performance and Damage Recovery

ABSTRACT This study presents a novel dual‐nozzle electrospinning technique for fabricating self‐healing nanofiber‐reinforced composites, designed to overcome limitations of conventional nanofiber‐based self‐healing systems. The method enables the simultaneous electrospinning of polyacrylonitrile (PAN) nanofibers individually loaded with epoxy resin and hardener, forming a continuous in situ self‐healing network within an abaca fiber/epoxy composite. Electrospinning parameters were optimized, with a 6 wt% PAN solution at 15 kV yielding uniform core‐shell nanofibers with minimal defects. Comprehensive characterization techniques including scanning electron microscopy (SEM), energy‐dispersive X‐ray spectroscopy (EDS), pH analysis, thermogravimetric analysis (TGA), Fourier‐transform infrared spectroscopy (FTIR), and X‐ray diffraction (XRD) confirmed fiber morphology, chemical encapsulation, thermal stability, and healing functionality. Permeability tests demonstrated effective resin migration, and Mode I fracture testing showed microcrack bridging and enhanced damage tolerance. Mechanical testing revealed a 4.98% increase in tensile strength and improved performance retention over multiple healing cycles. Compared to traditional approaches, this scalable method ensures uniform distribution of healing agents and improved material compatibility. The resulting composite demonstrates significant potential for developing durable, self‐healing materials suitable for aerospace, automotive, and structural applications, with added sustainability through natural fiber reinforcement.