Metrology

The Challenge of Thickness Control in Electrospinning

Traditional electrospinning workflows typically measure coating thickness after production (off-line). This creates delays in process adjustment, increases material waste, and raises the risk of producing off-spec batches resulting in batch rejection. In biomedical or pharma applications amongst others, where reproducibility and process validation are critical, post-process quality control becomes a significant bottleneck. Fluidnatek’s TMS (Thickness Metrology System) addresses this challenge by enabling real-time, contactless thickness monitoring directly during electrospinning on rotating collectors such as drums and mandrels. But moreover, the TMS can automatically compensate the thickness profile to make it superflat, achieving an unparalleled uniformity of fiber deposition.

Real-Time Thickness Monitoring During Electrospinning: Redefining precision and reproducibility in nanofiber manufacturing

The Fluidnatek TMS (Thickness Metrology System) uses an optical sensor and a special mechanical system able to continuously measure coating thickness all across the rotating collector, during the electrospinning process. Thickness data is displayed through the HMI and integrated into the Process Data Hub for visualization, recording and traceability. This approach enables operators to monitor coating build-up in real time without interrupting production or performing destructive testing, saving a lot of time and material wastage, and taking the batch rejection nearly to zero thanks to the automated material compensation function.

Key Benefits of Fluidnatek TMS (Thickness Metrology System)

• Real-time thickness measurement during electrospinning
• Contactless technology, does not affect the electrospinning process, non-destructive monitoring
• Automated thickness compensation
• Automatic process stop at target thickness
• Highly improved batch-to-batch consistency
• Reduced material waste and rejected batches
• Data logging for process traceability and validation
• Great repeatability
• Achieve great values of Cg, Cp, Cpk, Pp, Ppk, in your process
• Process Mode and Quality Mode for production and validation workflows

Reducing Development and Validation Bottlenecks

Instead of relying exclusively on offline measurements after production, the Fluidnatek TMS (Thickness Metrology System) provides continuous process visibility for thickness during the fiber deposition. Operators can identify deviations earlier, adjust process parameters more efficiently, and reduce trial-and-error iterations. In a complex process such as electrospinning, this is absolutely crucial.

This significantly accelerates process development workflows during R&D stages, while supports more robust process validation strategies in production stages.

Designed for Rotating Collectors and Biomedical Applications

The Fluidnatek TMS (Thickness Metrology System) is designed for electrospun materials produced on rotating collectors, including drums and mandrels. The system supports applications requiring tight control over coating thickness and demanding requirements for reproducibility.

The technology is particularly relevant for medical device manufacturing or pharma products, but also for other electrospinning applications requiring advanced thickness measuring and automated material compensation to achieve an incredibly flat profile of the electrospun layer.

Process and Quality Modes

• Process Mode enables continuous monitoring during production, including automated thickness compensation and operator-defined target thickness control.
  • In-line thickness measurement
  • Rotating collectors (drums and mandrels)
  • Up to 10 measurement points in axial line can be selected by the operator
  • Automated adjustment & compensation of thickness profile
  • Auto-stop trigger when target thickness is achieved
• Quality Mode provides high-resolution thickness mapping for process validation, consistency verification, and system-to-system matching.
  • High-resolution thickness mapping: thousands of points
  • Full characterization of thickness throughout the whole electrospun material
  • Ideal for OQ/PQ protocols, process optimization and verification of consistency batch-to-batch
  • Excellent tool to check and provide evidence of sytem-to-system matching (in a fleet of multiple Fluidnatek electrospinning units)

Switch between Process Mode for production and Quality Mode for detailed analysis.

Data Integration and GMP-Oriented Traceability

When integrated with Fluidnatek’s Process Data Hub, the Fluidnatek TMS (Thickness Metrology System) contributes to comprehensive process traceability by logging thickness data together with environmental and process parameters.

This supports validation-oriented workflows and aligns with Process Analytical Technology (PAT) and Quality by Design (QbD) principles commonly used in regulated manufacturing environments.

Integrated Within Fluidnatek Platforms

The Fluidnatek TMS (Thickness Metrology System) can be integrated into select Fluidnatek electrospinning platforms, including Fluidnatek LE-series systems for pilot-scale development and pre-industrial manufacturing, like Fluidnatek LE-500.

When combined with Fluidnatek’s Environmental Control Unit (ECU), the Fluidnatek TMS contributes to a more comprehensive process control strategy by correlating thickness data with temperature and humidity conditions.

Conclusion

Fluidnatek’s TMS (Thickness Metrology System) transforms electrospinning thickness control from a delayed, post-process activity into a in-line, real-time manufacturing capability. By enabling continuous monitoring, automated compensation, and integrated process traceability, the Fluidnatek TMS supports more reproducible, scalable, and efficient electrospinning production workflows, taking the risk of batch rejection nearly to zero.

Accelerate Your Electrospinning Process Development

Looking to reduce characterization bottlenecks and to improve process consistency? Fluidnatek’s integrated in-line thickness metrology (TMS) provides real-time process insight to support faster optimization, improved reproducibility, and scalable process development in electrospinning processes.

Contact our technical team to discuss more in detail the advantages and benefits of Fluidnatek’s in-line thickness metrology, and we will check whether it could be implemented in your specific electrospinning application.