Design and Optimization of Rotary Jet Spinning Process for

Production of Microfibers
Azad A1 & Ram Kumar A2
1 Associate Professor, Department of Manufacturing Engineering, Anna University, Chennai
2 Student, Department of Manufacturing Engineering, Anna University, Chennai

Microfibers were produced from Poly Vinyl Alcohol (PVA) using Fiber Forming Chamber Machine and examined
using Video Measuring System (VMS). The diameter of the fibers obtained was found to vary from 1μm to 10μm.
Parameters that govern the formation and size of fibers are nozzle rotating speed, solution concentration and
chamber temperature. A set of experiments based on Taguchi’s Design of Experiments were conducted to
ascertain the influence of the process parameters. It was found that the fiber diameter decreased as the nozzle
speed and solution concentration increased whereas the diameter increased initially when the temperature
increases and then the fiber diameter decreases.

Keywords: Microfiber, Rotary Jet Spinning, Taguchi

1 Introduction

Self-assembly, phase separation, and electrospinning are commonly used to produce nanofibers. Among these,
electrospinning is the most popular strategy, producing ultrafine fibers by electrically charging a droplet of
polymer liquid. Despite the versatility and popularity of electrospinning, high-voltage electrical fields,
imprecise control over fiber orientation, sensitivity to variability in solution conductivity, low production rate,
and difficulty in fabricating three-dimensional (3D) structures limit its application. There are few strategies to
expand the versatility of electrospinning; however, the need for reliable methods to generate well-characterized
and aligned micro- to nanoscale polymeric fibers persists. It is hypothesized that nanoscale fibers can be
produced by exploiting a high-speed nozzle to form a polymer jet which undergoes extensive stretching before
solidification. This process is known as Rotary Jet Spinning( RJS).

2 Rotary Jet Spinning

The RJS system consists of a reservoir with two side wall orifices that is attached to the shaft of a motor with
controllable rotation speed as shown in Figure 1(a). To facilitate the fiber collection a flexible air foil is placed
on the shaft above the reservoir. The polymer solution is continuously fed to the reservoir at a rate sufficient to
maintain a constant hydrostatic pressure and continuous flow. The resulting fibers were collected either on a
stationary, surrounding cylindrical collector or on coverslips which were held against the collector wall.
The fiber production process is composed of (i) jet-initiation to induce flow of the polymer solution through the
orifice, (ii) jet-extension to increase surface area of the propelled polymer stream, and (iii) solvent evaporation to
solidify and shrink the polymer jet.
 Buonarroti et al.

Figure 1 – (a) Basic apparatus for Rotary Jet Spinning. (b) Magnified view of the presumed formation mechanism of nanoscale fibers
through the RJS system, (i) jet-initiation, (ii) jet-extension, and (iii) solvent evaporation.(Badrosammy et al, 2010)

During the first step (Figure 1b-i), a combination of hydrostatic pressure and centrifugal pressure at the far end
of capillary14 exceeds the flow-resistant capillary forces and propels the polymer liquid through the nozzle
capillary as a jet. The outward radial centrifugal force stretches the polymer jet as it is projected toward the
collector wall (Figure 1b-ii), but the jet travels in a curled trajectory due to rotation-dependent inertia. Stretching
of the extruded polymer jet is critical in reducing jet diameter over the distance from the nozzle to the collector.
Concurrently, the solvent in the polymer solution evaporates, solidifying and contracting the jet (Figure 1b-iii).

Fiber forming chamber machine manufactured by VB Ceramics, Velachery, Chennai is used to produce
microfibers, Figure 2. The machine operates with a rotational speed range upto 6000 rpm and chamber
temperature upto 1200˚C.

Figure 2 – Fiber forming chamber

3 Experimental Work

Though the effect of individual parameters in the microfibers has been studied it is necessary to know the
combined effect of all variable and their interactions. This will throw more light on the process, hence this study
was undertaken. Fibers are produced using Fiber forming chamber machine. In this process, poly vinyl alcohol is
chosen for producing fibers.
3.1 Poly Vinyl Alcohol (PVA)

Poly(vinyl alcohol) (PVA) is a hydrophilic polymer which is of special interest for the application in medicine
owing to its excellent biocompatibility. Poly(vinyl alcohol) is one of the most ancient polymers and at the same
time the most popular one used in this field.
Poly(vinyl alcohol) (PVA) is a hydrophilic, semicrystalline polymer that has received much attention because of
its good chemical resistance, good thermal stability, good physical properties, excellent biocompatibility, and
inexpensiveness. Moreover, PVA is a hydrogel polymer—a hydrophilic polymer that forms a three-dimensional
network structure—that is capable of absorbing a large quantity of water.

3.2 Preparation of Polymer Solution

The PVA of type (-C2H4O)n with degree of polymerisation 1700-1800 and viscosity 25-32 cps was selected and
purchased from Loba Chemie Pvt Ltd., Mumbai The solvent used was distilled water. Solution of concentration
12%(w/v), 18%(w/v) and 24%(w/v) were prepared using magnetic stirrer as shown in figure 3.
From literature it was found that the solubility of PolyVinylAlcohol (PVA) increases significantly above 80˚C.
The solutions prepared under constant stirring using magnetic stirrer at 80˚C for 30 to 40 min. The stirring speed

Figure 3 – Magnetic Stirrer

was reduced for higher concentration as the pellet started wobbling. The solution was stirred until complete
dissolution of polymer occurred.

3.3 The Process

The solution prepared was fed into the rotating nozzle through a funnel. The rotating nozzle enclosed in the
heated chamber produced fibers which are deposited in the cylindrical chamber. The fiber formation can be seen
in figure 4.
 Buonarroti et al.

Figure 4 – Photograph of fiber formation

4 Taguchi’s Design of Experiments

In our project since we need to produce nanofibers of small diameter it is needed to optimize the experiment
design. So taguchi techniques are used. Level L9 experiment is used i.e three limits and 9 experiments. The
various variables and the levels are shown in table 1.

Table 1 – Process Variables and Levels

Process Variable Levels

1 2 3

Nozzle Speed (rpm) 2500 4000 5500

Solution Concentration (%w/v) 12 18 24

Temperature (˚C) 400 600 800

4.1 Taguchi’s Orthogonal Array

Taguchi L9 orthogonal array with 3 levels is used to optimize the different parameters for producing fibers with
small diameter. The fiber diameter at different experiment levels are shown in table 2.

Table 2 – Fiber diameter at different experimental levels

Experiment Column number and factors assigned Fiber mean diameter
No. (μm)
Nozzle Speed (rpm) Solution Concentration Temperature (˚C)
(%w/v)
1 1 1 1 No fiber formation

2 1 2 2 10

3 1 3 3 5

4 2 1 2 No fiber formation

5 2 2 3 5

6 2 3 1 4

7 3 1 3 Discontinuous beaded fiber

 8 3 2 1 3

9 3 3 2 1

5 Experimental Results

The images of fibers taken by using Video Measuring Sytem (VMS) at different experimental levels are shown
below in figure 5.

Figure 5 – VMS images of PVA fibers

From the obtained fibers for various samples Video Measuring System (VMS) was used to observe the diameter
and graphs were drawn based on the results. The diameter variation with different parameters is shown in figure
 Buonarroti et al.

6. From the graph we inferred that the fiber diameter decreased as the nozzle speed and solution concentration
increased whereas the diameter increased initially when the temperature increases and then the fiber diameter
decreases.

a) Nozzle Speed b) Solution Concentration

8

Fiber mean diameter (µm) 6

2
2500 4000 5500 18 24
c) Temperature
8

2
400 600 800

Figure 6 – Main Effects Plot of Fiber Mean Diameter

6 Conclusions and Scope for Future Work

Fibers of polyvinyl alcohol have been produced using rotary jet spinning technique and the various process
parameters have been identified using taguchi’s design of experiments for optimization. The fibers have been
observed using video measuring system and the diameter has been observed for optimization. There is scope for
producing nanofibers using the same technique by increasing the nozzle speed and using optimum solution
concentration and chamber temperature.

7 References

1) Mohammad R B, Holly A M, Josue A G And Kevin K P (2010), “Nanofiber Assembly by Rotary Jet-
Spinning” Nano Letters, vol 10, pp 2257- 2261.
2) Paula M, Holly A M, Mohammad R B, Josue A G, Mahadevan L and Kevin K P (2011), “A simple
model for nanofiber formation by rotary jet-spinning” Applied Physics Letter, 99, 203107.
3) Jayanth J, Dilip V, Narendran A, Kumaravel M and Radhakrishnan P(2009), “Design and optimisation
of electrospinning process for production of nanofibers” COPEN 6, E11-E17.