The electrospinning process uses an intense electric field to draw a polymer or ceramic precursor solution into ultra-fine threads. (1) High-Voltage Supply: A DC voltage (typically 10–30 kV) is applied between a metallic needle and a collector. (2) Taylor Cone Formation: As the voltage increases, the hemispherical surface of the solution at the needle tip elongates into a conical shape. (3) Jetting & Whipping: Once the electrostatic force overcomes the surface tension, a liquid jet erupts. As it flies toward the collector, the solvent evaporates and the jet undergoes "bending instability" (whipping), thinning the fiber significantly. (4) Collection: The solid fibers are deposited on a grounded collector (stationary plate or rotating drum) as a fibrous mat.

Electrospinning is notoriously sensitive to environmental conditions. Integrated Temperature (T) and Humidity (H) monitors are critical for reproducibility: (1) Humidity Control: High humidity can cause "beading" on the fibers or prevent the solvent from evaporating correctly, leading to fused fibers. For ceramic precursors used in SOFCs, moisture can trigger premature hydrolysis of the metal-organic precursors. (2) Temperature Control: Temperature affects the viscosity of your precursor solution. As we discussed with your interest in automated viscosity testing, even a small change in temperature during the spinning process can alter the fiber diameter by hundreds of nanometers.

The working mechanism of an electrospinning process is shown below: