Electrospun Nanofibers for Biomedical Use: A Detailed Review of Process Parameters, Morphological Control, and Advanced Fabrication Methods

Abstract

Electrospinning has emerged as a versatile and highly adaptable nanofiber fabrication technique capable of generating multifunctional scaffolds for biomedical applications, particularly in wound healing and regenerative medicine. This review provides a comprehensive analysis of the fundamental principles of electrospinning, the influence of solution, processing, and environmental parameters on nanofiber morphology, and the critical relationships between rheological behavior, chain entanglement, and fiber formation. Various classes of polymers, including synthetic, natural, and composite systems, are examined with respect to their spinnability, structural performance, biodegradation, and
application-specific suitability. Advanced electrospinning methods such as coaxial, triaxial, emulsion, bubble, centrifugal, and microfluidic-assisted systems are critically evaluated for their ability to achieve controlled drug delivery, compartmentalized architectures, porous and hollow morphologies, and stimuli-responsive performance. In addition, the review highlights emerging nanofiber platforms such as conductive, biomimetic, hydrogel-integrated, and smart responsive systems that synergistically integrate bioactivity, mechanical adaptability, and diagnostic or therapeutic functionalities. Key biomedical applications, including antimicrobial dressings, angiogenic scaffolds, aligned fibers for tissue guidance, and multidrug delivery constructs, are discussed, supported by recent advances demonstrating enhanced healing outcomes, infection control, and microenvironment modulation. By synthesizing current progress in fabrication technologies, material innovations, and clinically oriented design strategies, this review underscores the expanding potential of electrospun nanofibers as next-generation wound care and regenerative platforms. Future perspectives emphasize scalable manufacturing, green electrospinning approaches, real-time sensing integrations, and multifunctional hierarchical scaffolds capable of addressing complex wound pathophysiology.