Manufacturing of Nonwovens via Solution Blowing

Solution blowing is a manufacturing process used to produce nonwoven materials from polymers in solution. The solution is pumped through a spinneret, where high-velocity air is blown concentrically along each spun filament, which is stretched and collected on a drum or in a bath to form a nonwoven material.

Objective

Electrospinning is currently the most established method for producing advanced nonwoven materials with controllable functionalities and properties. Despite its advantages, the technique is limited in terms of scalability, which restricts its industrial exploitation. Solution blowing has recently emerged as a powerful alternative that addresses these limitations. The technique enables rapid and flexible prototype development, with great design freedom to introduce specific functionalities in the nonwoven materials. One of the major advantages is the increased control over the material’s structure – both in terms of creating three-dimensional structures and more complex geometries, such as tubular constructs. This has allowed for designing scaffold materials that resemble the native microstructure of human tissue, a key feature in regenerative medicine.
Fiber production via solution blowing shares many similarities with conventional wet spinning, meaning that existing expertise in this area can largely be transferred to the new technique.

Method

RISE offers services in research and development of processes for manufacturing nonwoven materials via solution blowing. We conduct experimental studies to develop new raw materials, optimize manufacturing processes, or produce nonwoven materials with specific functionalities. Through systematic testing and optimization of process parameters such as polymer concentration, addition of active substances, spinning parameters, coagulation bath composition, etc., we can tailor fiber properties to suit specific applications.

We have experience with a wide range of bio-based fiber-forming materials such as cellulose and its derivatives (e.g., hydroxypropyl cellulose), as well as marine materials such as chitosan, alginate, fucoidan, ulvan, and gelatin. We can also provide guidance on various production methods for materials with different application areas.

Solution Blowing at Lab Scale
Flexible equipment with the ability to control dimensions of both the finished nonwoven material and the individual fibers.

Fiber formation can occur either in dry conditions via drum collection or in a coagulation bath. Pre-coagulation in a water mist is also possible.
Spin dope volumes between 15 mL and 350 mL.
Capacity: 1–50 g dry fiber per day.

Material Analysis
RISE can analyze nonwovens using a variety of methods. We can perform chemical analyses and evaluate materials in terms of morphology using both optical and scanning electron microscopy (SEM), as well as determine porosity and wetting properties.

Delivery

Our goal is to deliver customized solutions for the production of functional nonwoven materials, tailored to meet each customer’s unique needs. Deliverables may include optimized process parameters summarized in a report or produced fiber materials with specific functionalities.