Fluidnatek LE-500
Fluidnatek LE-500 is a pilot-scale laboratory electrospinning and electrospraying machine to produce industrial pre-series of flat electrospun materials on roll-to-roll collector (material rolls), with high process control, guaranteeing consistency batch-to-batch, reproducibility and system-to-system matching. These characteristics make the Fluidnatek LE-500 electrospinner particularly suitable for demanding applications such as biomedical, medical devices and pharma; as well as other industrial applications with high requirements and demanding product specifications, thus requiring a tight process control.
Its standard configuration combines positive and negative high-voltage supplies, a 30-emitter linear spinning head, actively regulated exhaust system, and automated emitter-collector distance control, creating a platform built for process development, scale-up, and pilot production.
With batch volumes of up to 8 L of solution using two liquid feeding systems with 4 L reservoirs each, the Fluidnatek LE-500 is designed for longer production runs and reproducible semi-continuous operation. Depending on the solution, a batch can run for several days (solution-dependent), with automatic stopping available after a preset time.
The Fluidnatek LE-500 electrospinning machine can operate in either R&D mode or manufacturing mode, giving teams the flexibility to move from process development to larger-batch production on the same platform. This makes the Fluidnatek LE-500 a strong fit for industrial pre-series production of flat electrospun materials on a roll-to-roll collector (material rolls), where high throughput, consistency, and process control are all critical.
Designed to support a clear scale-up path, helping research teams to develop processes that can later be translated to higher-throughput industrial systems with fewer changes to the core recipe. Therefore the link between research areas and manufacturing areas, and the technology transfer between both areas (that have different goals), can be easily generated.
The platform supports multiple solution-feeding configurations, including semi-continuous solution feeding systems for larger volumes, and syringe pump-based options, allowing users to work with flowrates from milliliters up to several liters per hour, depending on the stage and the chosen machine configuration.
Environmental control is critical to ensuring consistent and reproducible production, it’s one of the key points indeed (not the only one though). The Fluidnatek LE-500 can be fitted with an Environmental Control Unit (ECU) capable of heating-cooling and drying-humidifying, having all degrees of freedom, with ranges of 18-45ºC for temperature and 10-80% for relative humidity (see psychrometric chart). Robust, stable environmental control for consistent manufacturing batch-to-batch.
The Fluidnatek LE-500 can incorporate in-line real-time metrology tools for area density and thickness, giving users direct feedback on deposition quality during the run. In applications where gsm or thickness control is critical, meaning the uniformity of the electrospun material produced is a key aspect, this capability helps validate the final product much more efficiently, giving the operator deep insights of the process in real time. The ultimate goal is taking the risk of batch rejection down, nearly to zero.
A multitude of advanced tools: tools geared towards Industry 4.0, needle-based & needle-less technology available, real-time data collection tools for process and equipment variables with configurable dashboard and alarm management, advanced process automation, electro-blow spinning ability, etc.
Highly upgradable electrospinning instrument designed to be a powerful pilot-production plant!
| Feature | Fluidnatek LE-500 Specification | Why It Matters |
|---|---|---|
| Equipment Type | Pilot-scale electrospinning and electrospraying platform for process development from initial concept, to process scale up, through to reproducible semi-continuous manufacture | One single electrospinning platform covers R&D stages, process scale up, and manufacturing. Research teams and production teams can make use of this equipment for different purposes. |
| Operating Modes | R&D mode and Manufacturing mode. Production of fibers and/or particles | Provides flexibility for both early-stage development and scalable pilot manufacturing workflows. Supports process continuity from the laboratory through to industrial pre-series of electrospun materials (ranging from handsheets to material rolls). |
| Construction | Stainless steel, aluminium, and glass frame and enclosures. Thermally insulated, chemically resistant, cleanroom-ready | Supports durable, easy-to-clean laboratory and pilot manufacturing operation. Compatible with organic solvents; frame is electrically earthed to prevent charge accumulation. |
| Footprint (Fluidnatek LE-500) | Machine: 1250 (W) × 1600 (D) × 2200 (H) mm Weight: ~ 800 kg (configuration dependent) | Designed for pilot and industrial pre-series production environments. Verify floor load capacity (~800 kg) and adequate clearance for the ECU (Environmental Control Unit) if selected. |
| Voltage Range | Dual HV: positive high-voltage power supply 0 to +30 kV or up to +50kV (for emitter), and negative high-voltage power supply 0 to −30 kV or up to –50kV (for collector), standard. Maximum potential difference: 100 kV. Bipolar high-voltage power supplies (−30 kV to +30 kV) can be alternatively integrated, for emitter and/or collector | Independent positive and negative power supplies improves process stability and fibre/particle deposition onto the collector. Bipolar power supplies enable polarity switching, increasing flexibility for processing solutions with different polarity. |
| Run Time | Up to several days per batch (solution-dependent). The touch-screen controls allow programming an automatic, smooth process stop and switch-off after a pre-set time | Enables extended semi-continuous production runs without operator intervention — a key advantage over smaller R&D platforms limited to hours. |
| Batch Volume | From <1 mL up to 8 L of spinning solution (using two semi-continuous peristaltic feeding systems with 4 L reservoir each) | Covers the full range from small feasibility studies (preliminary proof-of-concept) to large industrial pre-series batches on a single electrospinning platform. |
| Fiber / Particle Diameter | Typical range: 20 nm to 10 µm, depending on material, solution formulation, and process parameters | Enables a broad spectrum of fibre and particle sizes and morphologies — including porosity, alignment, and core-shell structures — to meet diverse application requirements. |
| User Interface | 7″ touch-screen (214 mm × 158 mm) with admin and operator access levels and individual passwords. Upgradeable to 12″ screen (410 mm × 320 mm) | Users can control all process parameters. Multi-user access levels support regulated manufacturing workflows (ISO/GMP). |
| Remote Communication | Integrated Ethernet module for remote diagnostics, and software upgrades by Fluidnatek service engineers | Minimises downtime. Enables fast remote diagnosis and software upgrades without requiring an on-site visit. Once the root cause of an issue has been found, fixing the equipment becomes much faster. The remote communication is key for this purpose. |
| Solution Feeding Systems | Pressurised liquid feeding system (up to 2 units) – Reservoirs: 250 mL, 1 L, and 2 L. Large-volume peristaltic feeding system with gravimetric dosage control (up to 2 units)l: 4 L reservoir, precise mass-flow control (g/h). Standard syringe pumps (up to 3 pumps). Up to 60mL volume each. High-pressure twin-channel syringe pumps (up to 3 units). High linear force. Up to 280mL each. High-pressure 4-channel syringe pumps (up to 2 units). Incredibly high linear force. Up to 560mL each. Tubeless solution dispensing system | A wide variety of solution feeding systems can be integrated in the Fluidnatek LE-500 electrospinning equipment, each solution feeding system consisting of different technologies and technical approaches, for multiple applications and requirements when it comes to solution dispensing and control. From low to high viscosities of the solution, from low volumes to high volumes required, lower or higher accuracy at solution dispensing, for R&D or for manufacturing purposes, or whether dead volume cannot be afforded, the broad range of solution feeding systems available for the Fluidnatek LE-500 enables to meet any requirement, for any application. |
| Solution Heating | Solution heating device in combination with the tubeless solution dispensing system | Some viscous solutions require heating to become more fluent so that can be more processable by electrospinning. The solution heating device can increase the temperature of a solution from room-temperature up to 120ºC. |
| Emitter–Collector Distance | Automated regulation of spinning distance Linear axis stroke: 200 mm (±1 mm) Spinning distance range: 0–300 mm (with exchangeable collector mounting platforms) | Automated emitter-collector distance control is a standard feature on the Fluidnatek LE-500, enabling touch-screen adjustment without opening the spinning chamber. Precise gap control and optimized emitter-collector distance is critical for jet stability, solvent evaporation, and fibre morphology. |
| Needle-Based Spinning Heads | Up to 10 spinning injectors with common rail → max 370 emitters/needles Single-phase, coaxial, and triaxial spinning heads available | Fluidnatek LE-500 supports a high throughput for manufacturing, but with flexibility allowing to go from one single-needle for R&D work up to 370 emitters for maximum industrial throughput. Field deflectors balance the electrical field in order to minimize the material wastage and to enhance the fiber deposition onto the collector. |
| Fluidnatek Needle-Less Technology | Three Slit Injector formats available: · 100 mm — one unit on standard holder; combinable with multi-emitter spinning heads · 400 mm — up to 4 units; higher throughput · 500 mm — up to 4 units; highest throughput; covers full roll-to-roll substrate width Up to 4 slit injectors can be installed | Slit Injectors generate multiple spontaneous jets while minimising open solution surface. The 500 mm length Slit Injector covers the full roll-to-roll width in a single pass. |
| Electro-Blow Spinning | Gas-assisted electrospinning: controlled gas/air flow to any coaxial spinning head | Combines electrospinning with blow spinning for increased production rates. Helps to prevent tip clogging with high-viscosity solutions and enables fiber deposition on less conductive collectors, where only the electrostatic force driving is not enough for an optimum fiber deposition. |
| Collector Types | Flat plate collector (stationary stainless-steel, 602 mm × 644 mm), rotating collectors: drums, mandrels and discs, roll-to-roll collector + conveyor belt, fiber-yarn collector module | Versatile collector options support flat sheets, tubular structures, aligned fibers, material rolls, and continuous electrospun yarn fabrication — all within the same platform. |
| Versatility at using different Substrates and Carriers | Conveyor belt mechanism for roll-to-roll collector | There are substrate/carrier materials that generate micro-weldings on the roll-to-roll, as a result generating wrinkles or even cracks in the worst scenario. The conveyor belt mechanism helps to prevent this situation from happening, therefore minimizing defects and issues when depositing fibers on substrates/carriers over the roll-to-roll collector. |
| Y-Axis Scanning Emitter Motion | Automated emitter motion (0–500 mm) | Ensures homogeneous deposition across large areas and rotating collectors. |
| Environmental Control | Fluidnatek Environmental Control Unit (ECU). Works in synchrony with the standard actively regulated exhaust system | Precise, stable environmental control is critical for reproducible fibre and particle morphology and consistent batch-to-batch results. Long-term stability (±1°C and ±3% relative humidity). The Fluidnatek Environmental Control Unit (ECU) enables heating/cooling and drying/humidifying. The ECU is self-contained and can be installed in a service corridor. HEPA filtration supports cleanroom and pharmaceutical manufacturing conditions by providing an ultra-clean environment in the spinning chamber. |
| Actively Regulated Exhaust System | Smart exhaust fan for optimized solvent extraction and enhanced operational safety | The active exhaust system communicates seamlessly with the Fluidnatek Environmental Control Unit (ECU) to optimize solvent extraction and maintain a constant slight negative pressure within the chamber, preventing vapor leakage. For enhanced safety, it features an automatic shutdown protocol in the event of ventilation failure—a standard requirement for all Fluidnatek climate control units. |
| Thickness Metrology | In-line thickness metrology in real-time for rotating collectors | In-line real-time metrology enables thickness-triggered process automation, ensuring every batch meets specification. It ensures uniformity (flat profile of the electrospun layer) and provides automated material compensation. Critical for validated pharmaceutical, medical device, and advanced filtration manufacturing. The Fluidnatek thickness metrology system takes the batch rejection nearly to zero. |
| Dual Spinning | Secondary spinning stage with separate high-voltage power supply and articulated mounting arm for dual spinning | Dual spinning allows the creation of composite or hybrid structures (e.g., two-component membranes made of two different types of fibers, or fibers + particules, or even the creation of the so called Janus fibers) with independent control of voltage and flow rate for each material.. |
| Advanced Software & Automation | Advanced tools for data collection, process automation, event management, batch control and remote monitoring and commanding, enabling comprehensive data integration and data-driven operations. | Demonstrating process consistency and repeatability is fundamental to high-level research. Fluidnatek High-Definition Process Data Hub facilitates this by monitoring over 40 process parameters and equipment signals, presenting them through an intuitive, customizable dashboard for comprehensive data-driven control. To complement this, Fluidnatek Programmable Multi-Step Recipe function introduces advanced automation. This enables the equipment to execute complex processes autonomously from start to finish—including time-dependent parameter adjustments—thereby eliminating variability and errors associated with human intervention. Audit Trail: Internally logs all system events and user actions during operation, ensuring the full traceability required for GMP (Good Manufacturing Practice) compliance. Batch Control: Automatically generates unique, non-overwritable batch numbers for every production run. These identifiers are linked to the data-logging system to ensure precise record-keeping for regulated manufacturing. Tamper-proof batch management is essential for biomedical and pharmaceutical applications, providing a significant advantage in other research and industrial fields. Remote equipment monitoring & commanding software tools, in the direction of Industry 4.0. Machine Qualification: Full support for ISO 13485 or GMP validation, including comprehensive documentation and on-site services such as IQ/OQ (Installation Qualification and Operational Qualification), FAT/SAT, and PQ (Performance Qualification) to ensure the equipment meets specific process requirements. . |
| Safety Features | Door interlock stops all hazardous functions on opening, electric arc detection, colour-changing warning beacon (HV status), electrically earthed chamber frame (prevents electrostatic charge), actively regulated exhaust with auto-shutdown on ventilation failure | Full protection against electrical discharge or electric arcs, solvent vapour accumulation, and unintended high-voltage exposure. Designed for safe operation in both laboratory and regulated manufacturing environments. |
| Cleanroom Compatibility | HEPA or ULPA inlet filter unit. HEPA or ULPA exhaust filter. UV-C germicidal lamps for chamber sterilisation. Up to ISO 5 spinning chamber (cleanliness level in particle counting) Glove ports available Hygienic design for cleanability and other clean-related aspects; solvent-resistant, thermally insulated enclosures. GMP/ISO certifiable; IQ/OQ documentation package available. | Cleanroom-ready configuration supports pharmaceutical, medical device, and advanced materials manufacturing. Advanced configuration for ultra-clean spinning in applications requiring clean environments. |
| Compliance & Qualification | CE compliant and independently verified | Compliant with European regulations for electrical safety and electromagnetic compatibility. Moreover, IQ/OQ (alternatively PQ) packages support validated workflows in regulated pharmaceutical and medical device manufacturing environments. Compliance documentation reduces time-to-validation and supports ISO 13485 and GMP requirements. |
Fluidnatek LE-500 is a pilot-scale electrospinning and electrospraying machine designed for process development from initial concept, to process scale up and through reproducible semi-continuous manufacture. It is a manufacturing tool to produce industrial pre-series of flat materials on roll-to-roll collector, with high process control, what in turn is translated into a great homogeneity, uniformity, consistency batch-to-batch, and system-to-system matching. It makes this equipment ideal for electrospun medical flat sheets (material rolls), as well as for pharmaceutical products. However, other formats such as continuous electrospun yarns can be produced, e.g. for applications like surgical sutures made out of biodegradable polymers, and other biomedical-related applications.
It supports both R&D and Manufacturing operating modes, accepts batch volumes from less than 1 mL up to 8 L, and can be configured with up to 370 emitters, roll-to-roll collector, and a full suite of GMP-oriented software tools.
Fluidnatek LE-500 supports up to 370 needle-based emitters when using the holder for 10 × 37-emitter linear spinning heads. Alternatively, up to four 400 mm or 500 mm Slit Injectors (needle-less technology) can be installed. The optimal number of spinning injectors and emitters for any given process depends on solution properties and must be evaluated for every specific formulation, but in any case this means the Fluidnatek LE-500 is a high-throughput electrospinning machine for manufacturing electrospun flat sheets in semi-continuous production (e.g. using the 370 emitters at a flowrate of 5mL per emitter, nearly 2L of solution per hour would be processed). Up to 8L of solution can be run in the Fluidnatek LE-500 electrospinning platform per batch.
The Fluidnatek Environmental Control Unit (ECU) regulates chamber temperature from 18°C to 45°C (±1°C) and relative humidity from 10% to 80% RH (±3%, temperature-dependent). The ECU provides HEPA-filtered conditioned air creating an ultra-clean environment in the spinning chamber, and works in synchrony with the actively regulated exhaust system for optimizing solvent vapour extraction all time, as well as for high-safety standards.
Yes. The Fluidnatek LE-500 electrospinner supports a complete set of optional GMP-oriented tools: data logging, the High-Definition Process Data Hub (40+ monitored parameters, deviation alarms), programmable multi-step recipes (up to 99 steps, 99 user profiles), audit trail, batch control with unique batch numbers, remote monitoring and commanding, external glove ports, and machine qualification documentation (IQ/OQ, FAT/SAT, and PQ upon request). All these functions support compliance with ISO 13485 and GMP frameworks for regulated pharmaceutical and medical device manufacturing environments.
The Fluidnatek LE-500 electrospinning machine can be equipped with a wide range of rotating collectors —including drums, mandrels, and discs—, static flat plate collector, as well as a roll-to-roll collection system and a specialized electrospun fiber-yarn collector for the production of continuous electrospun yarns.
Yes. Several syringe pumps are available with coaxial spinning heads for core-shell fiber and particle production. A 28-emitter linear coaxial multi-emitter spinning head is also available for pilot-scale core-shell manufacturing. A secondary spinning stage with independent high-voltage power supply enables simultaneous dual-material deposition. Triaxial spinning injectors for three-layer structures are also available with a third syringe pump.
ATEX-ready certification for explosive atmospheres, combined with CE electrical safety and comprehensive interlock systems for safe industrial operation..
The Fluidnatek LE-500 electrospinning platform is engineered and built for applications where tight and continuous control of process parameters is essential for consistent, reproducible output every time: that’s why this equipment is ideal for demanding electrospinning applications such as biomedical and pharmaceutical, as well as other applications having demanding requirements, where consistency, homogeneity, repeatability and system-to-system matching is a must. Both R&D and manufacturing operating modes are supported within the same platform.
The Fluidnatek Environmental Control Unit (ECU) introduces a conditioned air stream into the spinning chamber and regulates temperature from 18°C to 45°C (±1°C) and relative humidity from 10% to 80% (±3%), depending on temperature. The ECU enables heating, cooling and drying, humidifying, all degrees of freedom for total climate control in the spinning chamber. The ECU works together with the standard actively regulated exhaust system to maintain air exchange rates of up to 220 m³/h, preventing solvent vapor buildup and maintaining stable conditions throughout extended production runs. Along with the hygienic design of the Fluidnatek LE-500 electrospinning platform, conditioned air passes through a HEPA filter before entering the spinning chamber, supporting cleaner spinning conditions suitable for medical or pharmaceutical manufacturing.
The Environmental Control Unit (ECU) is a self-contained external unit connected to Fluidnatek LE-500 via insulated flexible ducting and a data cable. It can be installed beside the machine or in a separate service corridor. It can be purchased as an upgrade and installed at the customer facility.
For extremely high-throughput processes involving highly flammable solvents, a modification to the ECU enables connection to a nitrogen gas supply combined with an oxygen sensor, that way creating an inert atmosphere in the spinning chamber (ATEX), allowing safe operation at controlled oxygen concentrations.
Fluidnatek LE-500 accommodates multiple solution delivery configurations depending on process requirements:
The Fluidnatek LE-500 supports the widest range of spinning injector configurations in Fluidnatek range, from single-needle development work to high-throughput multi-emitter production arrays, with both needle-based and needle-less injectors.
The basic platform includes one linear single-phase multi-emitter spinning head with 30 parallel emitters in a linear array. However, linear spinning heads with 37 emitters each are available for maximum throughput across the full width of the roll-to-roll collector.
Up to 10 linear spinning heads (30 or 37 emitters/needles each) can be mounted using the dedicated holder for 10 heads with common rail, enabling a maximum of 370 emitters for the highest deposition rates. Up to 4 heads can also be mounted with the adjustable-spacing holder. Field deflectors are available for both 30- and 37-emitter spinning heads to minimize the electric field edge effect and improve deposition uniformity.
The Fluidnatek LE-500 electrospinner combines needle-based and needle-less technologies in a single platform, giving users flexibility to match the configuration to the material and the target deposition format. This makes it especially useful for teams that need to compare process strategies without moving to a different machine, bust just quickly replacing injectors and go.
Three Fluidnatek Slit Injector formats are available:
The Fluidnatek Slit Injectors minimize open solution surface compared with other needle-less designs, reducing undesirable evaporation. Flow rate remains controlled throughout the process, what gives a higher degree of process control, unlike many other needle-less technologies.
Multiple syringe pumps can be paired with coaxial and triaxial emitters for core-shell and three-layer fiber or particle fabrication. A linear coaxial multi-emitter spinning head with 28 emitters is also available for pilot-scale core-shell production. A secondary spinning stage with independent high-voltage power supply enables simultaneous dual-material deposition. The primary high-voltage power supply is also upgradeable to +50 kV, and negative high-voltage power supply for collector can be upgraded up to -50kV, giving a maximum potential difference between emitter and collector of 100 kV. Alternatively, All high-voltage power supplies can optionally be upgraded to bipolar supplies, ranging from negative to positive voltage range with the same power supply.
The roll-to-roll system (500mm width) equipped in the Fluidnatek LE-500 electrospinning platform, collects electrospun material onto a pre-loaded substrate in bidirectional (back-and-forth) motion, to offer the highest flexibility and accuracy at fiber deposition.
The user can program substrate speed, deposition length, and number of cycles via the touch-screen interface.
An conveyor belt mechanism prevents substrate adhesion to the roll-to-roll table surface, enabling use of non-conductive and mechanically sensitive substrates regardless of stiffness or elasticity: again, the highest versatility when it comes to different substrates/carriers handling.
The Fluidnatek universal rotating collector platform supports drums, mandrels, and disc collectors up to 300 mm in length, at speeds of 200–2000 rpm, for randomly deposited fibers or to generate fiber alignment instead. If using the encoded motor version of the universal rotating collector platform, it extends the lower speed range down to 20 rpm for those processes requiring very low rotating speeds, and provides rotational position information. Furthermore, balancing is also a crucial aspect: if a rotating collector vibrates more than it should, it will be affecting the electrospinning process. In this sense, the rotating collectors supplied by Fluidnatek are properly balanced in the rotating collector platform.
Standard collector sizes:
When combined with Y-axis scanning emitter motion, the drum collector enables fabrication of uniform fibrous sheets or coatings up to 300 mm × 620 mm.
The Fluidnatek LE-500 electrospinner supports GMP-oriented manufacturing workflows through a complete suite of optional software and documentation tools:
Electrospun fiber-yarn collector module: Produces continuous bundled nanofiber yarns. Features adjustable parameters to ensure an optimized collector process. Ideal for applications such as surgical yarns, special electrospun yarns made of biodegradable polymers, or coating of thin wires out of electrospun fibers.
The integration of Fluidnatek’s proprietary in-line contactless thickness metrology system enables real-time measurement on rotating collectors. This system automatically compensates fiber deposition to achieve a flat profile across the entire collector, ensuring exceptional uniformity. By nearly eliminating the risk of batch rejection, this tool guarantees consistency and reproducibility. Furthermore, it facilitates system-to-system matching across multiple Fluidnatek platforms —even when operated by different people in different locations and environments. While ideal for manufacturing stages, this Fluidnatek’s thickness metrology system also dramatically accelerates R&D and product development phases.
The platform also supports dual spinning configurations, enabling simultaneous deposition of two materials with different properties when the process calls for hybrid or composite structures, combining different fibers or depositing fibers + particles. That adds another layer of flexibility for development and pilot manufacturing.
Safety and compliance are integrated into the Fludnatek LE-500 design. The platform includes a door interlock, color-coded status beacon, an electrically earthed chamber frame, electric arc early detection, and an actively regulated exhaust system that helps extract solvent vapors and supports safer operation. For regulated workflows, the Fludnatek LE-500 electrospinner also supports documentation and functions relevant to ISO and GMP-oriented processes.
The Fluidnatek LE-500 is the pilot-scale and pre-industrial step in the Fluidnatek scale-up path (although for some users it works to all effects as an industrial electrospinning platform; it all depends on the production volumes needed in each case). Recipes developed on Fluidnatek LE-50 G2 or Fluidnatek LE-100 electrospinning platforms can be transferred to the Fluidnatek LE-500 to support process continuity from early-stage R&D toward semi-industrial manufacturing, preserving the fiber characteristics established during development. The consistent ECU (Environmental Control Unit) specifications, emitter-collector distance range, other features oriented towards tight process control, and advanced software environment across the Fluidnatek equipment range minimize the effort required at each scale transition.
From the Fluidnatek LE-500 electrospinner, further scale-up to the Fluidnatek HT big industrial platform follows the same recipe-based continuity approach, where only a bit of process readjustment is needed to scale up to a much larger platform.
Download technical sheet
ESP