Optimization of fiber diameter and bead density in electrospun TPU/PPC/GO composites using response surface methodology

This study employs Response Surface Methodology (RSM) to optimize the electrospinning parameters for fabricating thermoplastic polyurethane/polypropylene carbonate/graphene oxide (TPU/PPC/GO) composite fibers. The central goal was to understand the synergistic effects of GO reinforcement and processing conditions on the fiber morphology, which is critical for tailoring the material's performance in applications such as tissue engineering scaffolds. A Central Composite Design (CCD) was used to model the influence of TPU concentration (20–30 wt%), GO content (0–2 wt%), applied voltage (10–15 kV), and PPC/DMF(solvent) ratio (0–0.5) on two key responses (i. e. fiber diameter and bead density). Analysis of variance (ANOVA) of the thirty experimental runs revealed that TPU concentration (43.2% contribution) and the PPC/DMF ratio (30.4% contribution) were the dominant factors controlling fiber diameter. In contrast, the PPC/DMF ratio (32.9% contribution) was the most significant parameter in minimizing bead density, while GO content and voltage exhibited comparatively minor effects. The optimized parameters (25 wt% TPU, 1 wt% GO, 12.5 kV, PPC/DMF = 0.25) yielded a composite fiber mat with a minimized average fiber diameter of 0.486 μm and a low bead density of 43 beads/μm 2 . This systematic optimization provides valuable insights and a reliable framework for fabricating high quality TPU/PPC/GO fibrous scaffolds with controlled morphology for advanced applications. • RSM optimization of electrospun TPU/PPC/graphene oxide composites targeting fiber diameter and bead density. • TPU concentration dominates fiber diameter (43.2% contribution), while PPC/DMF ratio governs bead formation (32.9% contribution). • Graphene oxide content and voltage exhibit comparatively minor effects on the targeted morphological features within the studied ranges. • Optimal parameters (25 wt% TPU, 1 wt% GO, 12.5 kV, PPC/DMF=0.25) achieve minimized fiber diameter (0.486 μm) and bead density (43 beads/μm 2 ). • Statistically validated models (Adj. R 2 > 0.73) enable precise morphological control for tailored electrospun TPU/PPC/GO scaffolds.