Multiparametric Optimization of Fabrication of Electrospun PVA Nanofibers for Utilization as Wound Dressing Mats

Electrospun poly (vinyl alcohol) (PVA) nanofibers are promising materials for wound dressings because of their high porosity, large surface area, and structural similarity to the extracellular matrix. In this study, a Box–Behnken design was used to optimize the effects of applied voltage, flow rate, spinning distance, and needle gauge on the fabrication of electrospun PVA nanofiber mats using an 8% (w/v) PVA precursor solution. Fiber morphology, diameter, porosity, thickness, swelling capacity, and thermal properties were evaluated. Stable electrospinning conditions produced uniform, bead-free nanofibers with mean diameters ranging from 198.9 ± 3.6 to 228.7 ± 1.5 nm. Needle gauge and flow rate were identified as the most influential parameters affecting fiber diameter, while voltage and spinning distance showed interaction-dependent effects. Thinner fibers generated using finer needles resulted in higher porosity and enhanced swelling behavior, whereas larger needle diameters produced thicker and denser mats. Thermal analysis demonstrated good thermal stability, with degradation onset temperatures ranging from approximately 225 to 280 °C, and melting transitions consistently occurring at 190–193 °C. The results establish clear process–structure–property relationships and demonstrate that multiparametric optimization enables reproducible fabrication of PVA nanofibers with tunable characteristics relevant for wound-dressing applications.