Fabrication of 2D Textile Patterns Via Electrospinning - Achieving Negative Space Features

Electrospinning is a simple method of producing polymer fibers. Controlling the spatial arrangement of fibers to achieve patterned morphologies has attracted attention for various textile, filtration, and sensor applications. Metal templates such as grid electrode collectors create an “electric field lensing” effect that result in hierarchical self-assembly of the fibers. Overall, we aim to achieve fabrication of 2D textile patterns using electrospinning and such metal templates. Arbitrary garment shapes (e.g. single use mask, apron) were obtained by templating the grid electrode collector with insulating material. The focus of this work is to attain a negative space feature (e.g. holes) during electrospinning using nylon fibers spun from formic acid as a model system. Pattern features, specifically hole size and location, as well as utilizing various insulating methods such as air gaps are being explored. Air gaps and other insulating materials reduce fiber deposition on specified areas of the template. Using this approach, holes at the edge of the pattern (e.g. ear loops of masks, neck piece of an apron) have been achieved. In contrast, holes in the center of a pattern are more difficult to achieve as fibers accumulate over the desired negative space. Use of tape as insulating material over the desired hole produced the best results compared to foam or rubber: the area covered was 88% of the expected area. Foam and rubber decreased the area covered of the desired pattern to 86% and 60%, respectively. Experiments to understand the minimum distance from the center necessary to successfully achieve a hole as well as the smallest hole (relative to the width of the pattern) are currently underway.