Nanofibers possess high surface area and excellent porosity. Though nanofibers can be produced by a variety of techniques, electrospinning stands distinct because of its simplicity and flexibility in processing different polymer materials, and ability to control fiber diameter, morphology, orientation, and chemical component. Nonetheless, electrospun nanofibers are predominantly produced in the form of randomly oriented fiber webs, which restrict their wide use. Converting nanofibers into twisted continuous bundles, i.e., nanofiber yarns, can improve their strength and facilitate their subsequent processes, but remains challenging to make. Nanofiber yarns also create enormous opportunities to develop well-defined three-dimensional nanofibrous architectures. This review article gives an overview of the state-of-the-art techniques for electrospinning of nanofiber yarns and control of nanofiber alignment. A detailed account on techniques to produce twisted/non-twisted short bundles and continuous yarns are discussed.

Nanofibres prepared by electrospinning typically have randomly oriented fibrous structure. They have large surface-tovolume (or weight) ratio and excellent porous characteristic, which have shown enormous potential in diverse applications. However, electrospun nanofibres are often prepared in the form of randomly orientated fibrous web, which are fragile and difficult to be tailored in fibrous structures. Herein, we demonstrate a novel yarn electrospinning method which uses a rotating ring collector to convert newly electrospun nanofibres directly into a continuous yarn. The use of ring collector separates the yarn formation from the electrospinning zone. The deposition of later-spun nanofibres to the inner surface of fibrous cone eliminates hooked or curled nanofibres in the final yarn. The effects of polymer concentration and operating parameters on nanofibre and yarn morphology, diameter and the ring collector on yarn twist feature were examined. The nanofibre yarns had a surface twist angle up to 54.4°, and tensile strength as high as 93.6 MPa (elongation at break 242.6%). Increasing twist levels improves tensile strength and strain values.

A hybrid needle-needleless electrospinning technique has been developed to directly convert polymer solution into a highly-twisted, continuous nanofibre yarn.

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