Unique Fiber Morphologies from Emulsion Electrospinning—A Case Study of Poly(ε-caprolactone) and Its Applications

The importance of electrospinning to produce biomimicking micro- and nano-fibrous matrices is realized by many who work in the area of fibers. Based on the solubility of the materials to be spun, organic solvents are typically utilized. The toxicity of the utilized organic solvent could be extremely important for various applications, including tissue engineering, biomedical, agricultural, etc. In addition, the high viscosities of such polymer solutions limit the use of high polymer concentrations and lower down productivity along with the limitations of obtaining desired fiber morphology. This emphasizes the need for a method that would allay worries about safety, toxicity, and environmental issues along with the limitations of using concentrated polymer solutions. To mitigate these issues, the use of emulsions as precursors for electrospinning has recently gained significant attention. Presence of dispersed and continuous phase in emulsion provides an easy route to incorporate sensitive bioactive functional moieties within the core-sheath fibers which otherwise could only be hardly achieved using cumbersome coaxial electrospinning process in solution or melt based approaches. This review presents a detailed understanding of emulsion behavior during electrospinning along with the role of various constituents and process parameters during fiber formation. Though many polymers have been studied for emulsion electrospinning, poly(ε-caprolactone) (PCL) is one of the most studied polymers for this technique. Therefore, electrospinning of PCL based emulsions is highlighted as unique case-study, to provide a detailed theoretical understanding, discussion of experimental results along with their suitable biomedical applications.