Homogeneous field intensity control during multi-needle electrospinning via finite element analysis and simulation.

In the current study, finite element analysis is employed to simulate the process control of multi-needle electrospinning, by manipulating needle length, needle spacing, plastic casing of needle, and the way the voltage is applied to the needles, to facilitate the efficient production of homogeneous nanofibrous webs at high performance versus cost. The simulation results indicate that it is possible to control the field intensity homogeneity of multi-needle electrospinning process in terms of the vector sum of electric field intensity by adjusting the needle length, needle spacing, changing voltage application method and separating each needle with a plastic casing, etc. Measures such as capping each needle with a plastic casing, applying voltage directly to the needles, shortening the probed length of the needles at the edge sides, and reducing the distance between edge needles, as well as imparting additional voltage to the needles in the middle of the row could significantly decrease the field intensity of edge needles and thus improve the field intensity of the needles across one row and increase the potential of industrializing the needle type electrospinning technology.