Progress and technical challenges in electrospinning technology for continuous nanofiber yarn preparation

Electrospun nanofibrous yarns offer a unique platform for producing continuous nanofibers with potential applications in smart textiles, biomedical devices, filtration, and energy storage. However, translating the intrinsic high mechanical properties of single nanofibers to macroscopic yarns is constrained by inter-fiber load transfer inefficiencies, structural defects, and limitations in process scalability. This review provides a critical synthesis of recent advances in continuous yarn fabrication, encompassing conventional electrospinning methods-standard, multi-nozzle, melt, and rotary-and emerging paradigms such as in-line spinning, electrospraying, and solvent blowing. We examine how material selection, process parameters, fiber morphology, and structural design influence mechanical performance, uniformity, and functional properties. Key challenges for industrial translation, including throughput-uniformity trade-offs, reproducibility, and environmental impacts of solvent-based processes, are discussed. Finally, we outline forward-looking strategies integrating hybrid manufacturing, functional integration, and AI-driven process control to enhance reproducibility and scalability, thereby facilitating the development of high-performance, sustainable nanofiber yarns suitable for advanced functional applications.