Roll-to-Roll Production of Spider Silk Nanofiber Nonwoven Meshes Using Centrifugal Electrospinning for Filtration Applications

Filtration systems used in technical and medical applications require components for fine particle deep filtration to be highly efficient and at the same time air permeable. In high efficiency filters, nonwoven meshes, which show increased performance based on small fiber diameters (e.g., using nanofibers), can be used as fine particle filter layers. Nanofiber nonwoven meshes made by electrospinning of spider silk proteins have been recently shown to exhibit required filter properties. Needle-based electrospinning, however, is limited regarding its productivity and scalability. Centrifugal electrospinning, in contrast, has been shown to allow manufacturing of ultrathin polymer nonwoven meshes in an efficient and scalable manner. Here, continuous roll-to-roll production of nonwoven meshes made of recombinant spider silk proteins is established using centrifugal electrospinning. The produced spider silk nanofiber meshes show high filter efficiency in the case of fine particulate matter below 2.5 µm (PM2.5) and a low pressure drop, resulting in excellent filter quality.