Review: advancements in fibrous aerosol filtration across experimental analysis, numerical modeling, and fabrication technologies

The increasing incidence of aerosol-related pulmonary diseases has intensified the need for efficient fibrous filtration technologies capable of capturing ultrafine particles with low pressure drop. Although nonwoven fibrous filters are widely used in medical, industrial, and ventilation systems, their complex internal structures and multiscale transport mechanisms remain insufficiently understood. This review examines the theoretical foundations of aerosol filtration, including single-fiber capture mechanisms and the concept of the most penetrating particle size. In addition, electrostatic interactions, including charge generation, transport, and stability, are incorporated to extend conventional mechanical filtration frameworks. Particular attention is given to flow–particle interactions within fibrous media. We then discuss current approaches for constructing three-dimensional representations of filter structures and highlight how structural assumptions influence the reliability of numerical simulations. Computational fluid dynamics modeling, particle tracking, deposition modeling, and clogging simulations are critically evaluated, with emphasis on commonly adopted assumptions such as homogeneity and steady-state flow. Experimental methodologies for filtration testing are also reviewed, including aerosol generation, particle measurement, and pressure-drop characterization. Instrumentation limitations and measurement uncertainties are discussed. Finally, recent advances in fiber fabrication techniques, including electrospinning, meltblowing, bubble electrospinning, and supersonic solution blowing, are summarized. These fabrication approaches are further analyzed through a material–process–performance perspective, linking fiber morphology and charge behavior to filtration efficiency. The interplay between structural parameters, operating conditions, and aerosol characteristics is analyzed to clarify their combined influence on filtration performance. By identifying unresolved modeling limitations and discrepancies between theoretical predictions and real-world conditions, this review highlights key gaps in current understanding. It integrates filtration theory, electrostatic effects, and fabrication-induced material properties into a unified framework. This approach enables more predictive design of next-generation fibrous filters. Graphical abstract