Electrospinning is a powerful method for creating micro- and nanofibres used in fields such as biomedical engineering, filtration, and energy storage. A key factor in successful electrospinning is the choice of solvent, which affects how well the polymer dissolves, the properties of the solution, the fibre quality, and the overall efficiency of the process. However, commonly used solvents like tetrahydrofuran (THF) and hexafluoroisopropanol (HFIP) pose serious health and environmental risks due to their toxicity and volatility. This review examines the influence of solvent properties, including volatility, surface tension, viscosity, and dielectric constant, on fibre formation and process stability. It covers different types of solvent systems, including single, binary, and green solvents, that analyse polymer–solvent compatibility using tools such as Hansen solubility parameters, with examples from both synthetic (PCL, PLA) and natural polymers (chitosan, silk fibroin). This review also discusses the toxicological impact and regulatory concerns of widely used solvents, especially for biomedical use (wound healing). It emphasises the need for environmentally friendly alternatives, such as water, ethanol, acetic acid, and ionic liquids. On the contrary, it suggests strategies for designing safer solvents, highlights case studies, and points towards future research needs like solubility databases, predictive modelling and scalable green electrospinning methods.
Pan et al. (Mon,) studied this question.