Effects of humidity and solution viscosity on electrospun fiber morphology

Electrospinning is a popular technique to fabricate tissue engineering scaffolds due to the exceptional tunability of fiber morphology that can be used to control scaffold mechanical properties, degradation rate, and cell behavior. Although the effects of modulating processing or solution parameters on fiber morphology have been extensively studied, there remains limited understanding of the impact of environmental parameters such as humidity. To address this gap, three polymers (poly(ethylene glycol) [PEG], polycaprolactone [PCL], and poly(carbonate urethane) [PCU]) were electrospun at a range of relative humidities (RH = 5%-75%) and the resulting fiber architecture characterized with scanning electron microscopy. Low relative humidity (< 50%) resulted in fiber breakage for all three polymers due to decreased electrostatic discharge from the jet. At high relative humidity (> 50%), three distinct effects were observed based on individual polymer properties. An increase in fiber breakage and loss of fiber morphology occurred in the PEG system as a result of increased water absorption at high relative humidity. In contrast, surface pores on PCL fibers were observed and hypothesized to have formed via vapor-induced phase separation. Finally, decreased PCU fiber collection occurred at high humidity likely due to increased electrostatic discharge. These findings highlight that the effects of relative humidity on electrospun fiber morphology are dependent on polymer hydrophobicity, solvent miscibility with water, and solvent volatility. An additional study was conducted to highlight that small changes in molecular weight can strongly influence solution viscosity and resulting fiber morphology. We propose that solution viscosity rather than concentration is a more useful parameter to report in electrospinning methodology to enable reproduction of findings. In summary, this study further elucidates key mechanisms in electrospun fiber formation that can be utilized to fabricate tissue engineering scaffolds with tunable and reproducible properties.