Real‐Time Characterization of Polypropylene Jet Dynamics in Melt Electrospinning Using Laser Diffraction and Image Analysis

This study explores the dynamic behavior and morphology of polypropylene (PP) jets during melt electrospinning under varying high‐voltage conditions. Real‐time observations are conducted using cameras and a He–Ne laser to capture jet and droplet behavior. This work aims to establish a quantitative framework for understanding and controlling jet behavior during melt electrospinning. The results show that increasing the applied voltage leads to more stable jet formation, smaller droplet sizes, and higher whipping frequencies due to enhanced electric fields. Laser diffraction analysis reveals a continuous decrease in jet diameter from the nozzle to the collector, with a significant reduction observed at 35 kV. Scanning electron microscope confirms this trend, showing average fiber diameters of 41.88 ± 11.40 μm at 25 kV, 18.60 ± 3.30 μm at 30 kV, and 11.91 ± 3.20 μm at 35 kV. Refractive index predictions using Mie scattering theory range from 1.480 to 1.503, increasing as jet diameter decreases. These findings highlight the value of real‐time monitoring techniques such as laser diffraction for characterizing jet dynamics and optimizing melt electrospinning parameters. The proposed approach also supports the development of inline process monitoring systems for scalable production of solvent‐free nanofibers applicable in filtration, energy, and technical textiles.