High throughput fabrication of nanofibrous yarns produced by AC electrospinning

Nanofiber yarns offer unique opportunities for developing next-generation flexible materials that combine nanoscale functionality with macroscopic structural integrity. Their high surface-to-volume ratio, fine open porosity, and fibrous morphology enable applications in tissue engineering, drug delivery, filtration, sensors, energy storage, and functional textiles. However, the transition of nanofiber yarn technology from laboratory to industrial scale has been limited by low productivity and poor control over morphology, linear density, twist, and tensile strength. Here, we report a simple, scalable, and robust method for the continuous production of 100% nanofiber yarns using high-throughput needleless and collectorless alternating-current (AC) electrospinning. A plume of nanofibers generated from a rotating disc spinning-electrode is continuously deposited on a rotating drum and withdrawn through a spinning triangle, where a twirling device imparts controlled twist. Using this setup, nanofiber yarns composed of poly(vinyl butyral) (PVB), poly(ε-caprolactone) (PCL), polyamide 46 (PA46), and poly(vinyl alcohol) (PVA) were produced at speeds up to 55 m min⁻¹ with a 200 mm disc spinning-electrode. Scanning electron microscopy revealed densely packed nanofibrils within the yarn cross-sections and a dominant pore size around 1 µm. The yarns were braided and woven into scaffolds supporting cell adhesion and proliferation. This high-performance alternating-current electrospinning approach effectively bridges the gap between electrospun fibers—whose two of three characteristic dimensions reside in the nanoscale—and macroscopic textile manufacturing, thereby enabling a practical and scalable pathway for the industrial production of nanofiber yarns for biomedical and advanced material applications.