Tailoring electrospun PLA nanofiber scaffolds: Influence of binary solvent systems and flow rate on morphological, mechanical, and biological performance

This study investigates the influence of binary solvent systems and flow rates on the production of poly(lactic acid) (PLA) nanofibers via electrospinning. Different dichloromethane (DCM)/dimethylformamide (DMF) ratios (30/70, 50/50, and 70/30, v/v) were evaluated in combination with flow rates of 1.0, 1.5, and 2.0 mL/h. Scanning electron microscopy (SEM) revealed that the 30DCM/70DMF system at 1.0 mL/h produced the most uniform and bead-free fibers. Mechanical characterization demonstrated that this formulation also exhibited significantly higher tensile strength than the other solvent systems. Although solvent composition significantly affected fiber morphology and mechanical performance, all samples exhibited hydrophobic behavior and high cell viability (>90%). These results indicate preserved cytocompatibility under the conditions tested. These findings demonstrate that solvent composition is a key parameter governing electrospinning stability, fiber architecture, and tensile strength, establishing a clear relationship between processing conditions, structural characteristics, mechanical performance, and cytocompatibility.