Multiparametric Optimization of Fabrication of Electrospun PVA Nanofibers for Utilization as Wound Dressing Mats

Electrospun nanofiber-based wound dressings have gained significant attention due to their structural similarity to the extracellular matrix and their ability to support optimal healing conditions. In this study, the fabrication of poly(vinyl alcohol) (PVA) nanofibers was systematically optimized using a multiparametric approach to achieve reproducible morphology and functional performance suitable for wound care applications. A Box–Behnken experimental design (BBD) was employed to evaluate the effects of key electrospinning parameters, including applied voltage, flow rate, spinning distance, and needle gauge. Nanofiber morphology, diameter, uniformity, and porosity were characterized using scanning electron microscopy and image analysis, while mat thickness, swelling behavior, and thermal stability were also assessed. Stable electrospinning conditions resulted in uniform, bead-free nanofibers with mean diameters ranging from approximately 198 to 228 nm. Flow rate and needle gauge were identified as the most influential factors affecting fiber diameter, while voltage and spinning distance exhibited interaction-dependent effects. A strong correlation was observed between fiber diameter and functional properties, where thinner fibers exhibited higher porosity and improved swelling capacity, supporting efficient exudate management. Thermogravimetric analysis confirmed that all materials possessed adequate thermal stability for biomedical use. This study demonstrates that systematic multiparametric optimization enables precise control over the structure–property relationships of electrospun PVA nanofibers. The findings provide a robust framework for designing nanofiber-based wound dressings with tailored performance characteristics and improved reproducibility.