<p>This study investigated the effects of key process parameters on fiber diameter variation during the electrospinning process, using the Taguchi method. The parameters studied include voltage, polystyrene (PS) concentration, distance from injector to collector, and flow rate, each tested at three levels. A Taguchi L9 (3⁴) orthogonal array was utilized to construct nine experiments, and the S/N ratio approach (with the “smaller is better” criterion) was applied to determine optimal parameter levels. The results indicated that PS concentration is the most influential factor (45.7%) affecting the variation of fiber diameter. The optimal conditions identified were 22.5&#xa0;kV voltage, 20&#xa0;cm distance, 20% PS concentration, and a 0.05&#xa0;ml/min feed rate, resulting in a reduced variation of fiber diameter of 1.326&#xa0;µm. This result showed an 11.007% reduction compared to the previous best result (experiment no. #6, 1.490&#xa0;µm). This finding was then confirmed through a linear mathematical modelling, statistical software (Minitab), and an additional validation experiment, demonstrating that the Taguchi method provides a simplified yet effective approach to optimize the electrospinning process with fewer experiments than traditional factorial designs. The outcomes hold potential for advancing micro- and nanofiber electrospinning applications and can serve as a foundation for future equipment development and educational resources.</p> Graphical abstract <p>Integrated framework for electrospun fiber fabrication and process optimization.</p>