It is widely known that molten polymers may be electrospun; however there are comparatively few articles on melt electrospinning in the literature. Electrospinning from the melt may allow new approaches to certain aspects of electrospinning, particularly overcoming the technical restrictions governed by solvent accumulation and toxicity.

Both high and low melting point polymers can be melt electrospun, and electrospinning directly onto cells is feasible. In this research, biocompatible amphiphilic block copolymers of polyethylene glycol and poly(e-caprolactone) (PEG-b-PCL) are used, and their viscosity tailored through blending with other polymers. We also demonstrate that polypropylene fibers can be reduced from 35±8 mm in diameter, to 840±190 nm with a viscosity-reducing additive. Melt electrospun blends of PEG-b-PCL and PCL produced fibers with micron-scale diameters (2.0±0.3 mm); however this was lowered to 270±100 nm by using the gap method of alignment for collection, suggesting further extrusion of the fibers upon collection.

In preliminary investigations for tissue engineering applications, fibroblasts directly adhere to the electrospun fibres, wrapping around the fibres and attaching to multiple fibres. Since cells cultured in vitro can be used as collectors for melt electrospinning, the process promises to intimately combine the cell with the electrospinning collection process. In numerous ways, solvent accumulation has dictated the manner in which electrospinning has been performed. At the research level most electrospinning is perform in well-ventilated areas, and attaining industrial scale manufacture is associated with significant ventilation systems. Melt electrospinning is readily performed in a variety of spaces, ranging from confined and sealed vessels to cell culture hoods.

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