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<p>Melt electrospinning (MES) and melt electrowriting (MEW) have emerged as solvent-free fiber fabrication technologies that bridge conventional electrospinning and additive manufacturing. Compared with solution electrospinning, melt-based processes exhibit fundamentally different jet behaviors arising from high viscosity and low electrical conductivity, leading to reduced electrohydrodynamic instabilities and extended straight-jet regions. These characteristics enable two complementary processing routes: high-throughput fiber production through MES and precise architectural fabrication through MEW. This review provides a comprehensive overview of MES and MEW technologies, covering fundamental principles, processing setups, jet-taming strategies, and mechanisms governing fiber diameter reduction. Particular emphasis is placed on the roles of viscosity, electrical responsiveness, thermal modulation, and electric-field engineering in controlling jet stability and fiber morphology. Recent developments in needleless and differential melt electrospinning, gas-assisted processing, and robotic integration are highlighted as key advances toward scalable and intelligent manufacturing. Processing expansion through hybrid fabrication and functional additives is also discussed, along with representative applications in filtration, biomedical engineering, energy, and multifunctional systems. Finally, MES and MEW are presented as a continuous technological spectrum progressing from surface-driven fiber fabrication toward architecture-driven manufacturing, emphasizing future directions toward hierarchical structures, digital process control, and data-driven process automation.</p>

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Recent Advances in Melt Electrospinning and Melt Electrowriting: Jet Taming, Fiber Diameter Control, and Emerging Applications

  • 期刊论文

  • 发表日期：

    2026年4月15日

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  • Hyunchul Ahn,
  • Hajoong Kim,
  • Mingyu Park,
  • Byoung-Sun Lee

摘要

Melt electrospinning (MES) and melt electrowriting (MEW) have emerged as solvent-free fiber fabrication technologies that bridge conventional electrospinning and additive manufacturing. Compared with solution electrospinning, melt-based processes exhibit fundamentally different jet behaviors arising from high viscosity and low electrical conductivity, leading to reduced electrohydrodynamic instabilities and extended straight-jet regions. These characteristics enable two complementary processing routes: high-throughput fiber production through MES and precise architectural fabrication through MEW. This review provides a comprehensive overview of MES and MEW technologies, covering fundamental principles, processing setups, jet-taming strategies, and mechanisms governing fiber diameter reduction. Particular emphasis is placed on the roles of viscosity, electrical responsiveness, thermal modulation, and electric-field engineering in controlling jet stability and fiber morphology. Recent developments in needleless and differential melt electrospinning, gas-assisted processing, and robotic integration are highlighted as key advances toward scalable and intelligent manufacturing. Processing expansion through hybrid fabrication and functional additives is also discussed, along with representative applications in filtration, biomedical engineering, energy, and multifunctional systems. Finally, MES and MEW are presented as a continuous technological spectrum progressing from surface-driven fiber fabrication toward architecture-driven manufacturing, emphasizing future directions toward hierarchical structures, digital process control, and data-driven process automation.