Electrospinning evolved as a powerful technology to produce membranes consisting of nano- to micron-scaled fibers offering unique membrane properties due to the extremely high surface-to-volume ratio and high membrane porosity. However, this technology is often far removed from a green and environmentally-friendly process, as it employs solvents with issues such as high flammability, toxicity, difficult disposal, or energy-intensive synthesis. Indeed, the most commonly used solvents in the electrospinning field are halogenated (e.g. chloroform, trifluoroethanol) and toxic solvents (e.g. dimethylformamide), the use of which is now restricted by the Chemical Control Regulation in the European Union (REACH). This is especially important when considering the commercialization of electrospun products due to the more limited solvent choice. In order to render electrospinning more attractive as a commercial technique and further improve scalability, solvent alternatives and other green routes have to be established, which adhere to societal and legal restrictions especially in regard to the environmental and health impact. Therefore, this review provides the current ecological and economical context of this technology, and summarizes recent approaches towards green electrospinning. Since electrospinning from solutions and dispersions constitutes the predominantly used form of this technique both in research and industry, the focus of this work is set on the use of solvents or solvent mixtures classified exclusively by the term “green”. The approaches presented comprehensively cover the production of polymeric fibers via solution, emulsion, suspension, and in situ cross-linking electrospinning.

Structural and functional properties of polymer composites based on carbon nanomaterials are so attractive that they have become a big challenge in chemical sensors investigation. In the present study, a thin nanofibrous layer, comprising two insulating polymers (polystyrene (PS) and polyhydroxibutyrate (PHB)), a known percentage of nanofillers of mesoporous graphitized carbon (MGC) and a free-base tetraphenylporphyrin, was deposited onto an Interdigitated Electrode (IDE) by electrospinning technology. The potentials of the working temperature to drive both the sensitivity and the selectivity of the chemical sensor were studied and described. The effects of the porphyrin combination with the composite graphene–polymer system appeared evident when nanofibrous layers, with and without porphyrin, were compared for their morphology and electrical and sensing parameters. Porphyrin fibers appeared smoother and thinner and were more resistive at lower temperature, but became much more conductive when temperature increased to 60–70 °C. Both adsorption and diffusion of chemicals seemed ruled by porphyrin according its combination inside the composite fiber, since the response rates dramatically increased (toluene and acetic acid). Finally, the opposite effect of the working temperature on the sensitivity of the porphyrin-doped fibers (i.e., increasing) and the porphyrin-free fibers (i.e., decreasing) seemed further confirmation of the key role of such a macromolecule in the VOC (volatile organic compound) adsorption.

Light polymeric soundproofing materials (density = 63 kg/m³) of interest for the transportation industry were fabricated through electrospinning. Blankets of electrospun polyvinylpyrrolidone (average fiber diameter = (1.6 ± 0.5) or (2.8 ± 0.5) μm) were obtained by stacking disks of electrospun mats. The sound absorption coefficients were measured using the impedance tube instrument based on ASTM E1050 and ISO 10534–2. For a given set of disks (from a minimum of 6) the sound absorption coefficient changed with the frequency (in the range 200–1600 Hz) following a bell shape curve with a maximum (where the coefficient is greater than 0.9) that shifts to lower frequencies at higher piled disks number and greater fiber diameter. This work showed that electrospinning produced sound absorbers with reduced thickness (2–3 cm) and excellent sound-absorption properties in the low and medium frequency range.

Transparent face masks are the ultimate solution for improving communication during pandemic times while at the same time slowing the spread of pathogens. Here, we demonstrate an easily scalable process consisting of directly electrospinning polyamide nanofibers onto a mechanical stable substrate made of poly(lactic acid) by a needleless setup for the production of transparent filter material. Filtration tests against NaCl and fructose aerosols and pressure drop tests were performed and compared with the European standard for medical face masks (EN 14683:2019) and the Swiss rule for community masks (SNR 30000:2021). The filter showed outstanding transparency (∼70% transmittance in the visible-light range), 89% filtration efficiency against PM_1.0, and a pressure drop of 6.5 Pa/cm².

Humic acids (HA) exhibit fascinating multifunctional features, yet degradation phenomena as well as poor stability in aqueous environments strongly limit their use. Inorganic nanoparticles are emerging as a powerful interface for the development of robust HA bio-hybrid materials with enhanced chemical stability and tunable properties. Hybrid organic-inorganic SiO₂/HA nanostructures were synthesized via an in-situ sol-gel route, exploiting both physical entrapment and chemical coupling. The latter was achieved through amide bond formation between carboxyl groups of HA and the amino group of 3-aminopropyltriethoxysilane (APTS), as confirmed by Fourier-Transform Infrared (FTIR) and Nuclear Magnetic Resonance (NMR) spectroscopy. Monodisperse hybrid nanoparticles about 90 nm in diameter were obtained in both cases, yet Electron Paramagnetic Resonance (EPR) spectroscopy highlighted the different supramolecular organization of HA. The altered HA conformation was reflected in different antioxidant properties of the conjugated nanoparticles that, however, resulted in being higher than for pure HA. Our findings proved the key role of both components in defining the morphology of the final system, as well as the efficacy of the ceramic component in templating the HA supramolecular organization and consequently tuning their functional features, thus defining a green strategy for bio-waste valorization.