Modeling of the electrospinning process using rheological and physical chemistry approaches and enhancement of electrospun mats

Abstract Fiber diameter and defect-free morphology, particularly the suppression of bead formation, are critical to the performance of electrospun fibers. This study employs complementary physicochemical and rheological approaches to predict fiber morphology using poly(butylene succinate) (PBS) dissolved in a DMF–chloroform solvent blend, with poly(methyl methacrylate) (PMMA) incorporated in selected samples. Guided by Colby’s theory, specific viscosity measurements identified 6.067 % PBS as the minimum concentration for fiber formation and 21 % PBS as the concentration producing uniform, defect-free fibers, while the critical entanglement concentration (Ce) was determined from specific viscosity. From a rheological perspective, the interactions among electrical, elastic, and capillary forces were analyzed using Feng’s Slender Body model, which yielded results consistent with Yu and Fridrikh’s formulations while avoiding reliance on imaging-derived jet parameters. The specific-viscosity-based approach provided predictions with relatively low error margins of approximately 2–5 % compared with more complex rheological methods. Although the model slightly overestimated fiber morphology parameters, it provides a practical approach for predicting electrospinning outcomes and defect formation.