ABSTRACT
Electrospraying and electrospinning are cutting-edge nanofabrication techniques that enable the controlled production of nanoparticles and nanofibers with tailored physicochemical properties. These technologies have gained widespread attention in pharmaceuticals, biotechnology, and materials science, particularly for their applications in drug delivery, tissue engineering, and advanced biomedical devices. The ability of electrospraying and electrospinning to generate nanostructures with high surface area, tunable porosity, and controlled release profiles has positioned them as promising tools for next-generation medical innovations. Despite their advantages, the scalability of these techniques remains a critical challenge, limiting their transition from laboratory-scale research to industrial manufacturing. Key obstacles include low process throughput, instability of the electrohydrodynamic jet, and variations in product uniformity. To address these limitations, researchers have explored novel scale-up strategies, including multi-nozzle and nozzleless configurations, hybrid processing methods, and computational modeling to optimize process stability. Furthermore, the development of solvent-free techniques, such as melt electrospinning and alternating current-driven processes, has expanded the environmental and industrial viability of these approaches. This book chapter provides an in-depth analysis of the challenges and advancements associated with scaling up electrospraying and electrospinning for high-throughput production. It explores the impact of process modifications on nanomaterial properties, discusses the commercialization of electrospraying- and electrospinning-based pharmaceutical products, and highlights regulatory, economic, and environmental considerations. By addressing these critical factors, electrospraying and electrospinning hold the potential to revolutionize nanotechnology applications, paving the way for groundbreaking developments in drug delivery, biomedical engineering, and beyond.
