The growing demand for high-value medical dressings, wearable sensors, and functional protective materials has increased the need for microfiber nonwoven fabrics offering high elasticity, low weight, and reliable mechanical strength. However, conventi...
The growing demand for high-value medical dressings, wearable sensors, and functional protective materials has increased the need for microfiber nonwoven fabrics offering high elasticity, low weight, and reliable mechanical strength. However, conventional melt-blown (MB) systems rely on continuous high-temperature compressed air, resulting in substantial energy consumption and limited adaptability for small-scale or customized production. To overcome these limitations, this study introduces an Air-Stretching Melt Spinning process utilizing a compact Air Amplifier, which generates instantaneous tensile forces without the use of heated air. This approach not only supports localized laying of fibers but also aligns with current manufacturing trends toward energy-efficient, flexible, and miniaturized equipment Thermoplastic Polyurethane (TPU) webs were fabricated under varying extrusion rates, the gap from nozzle to air-amplifier, and air pressures to investigate fiber diameter control, web structure, air permeability, and tensile behavior. The process produced uniform ultrafine fibers, while mechanical properties improved with optimized extrusion and stretching conditions. Overall, the proposed method is expected to offer a low-energy, highly controllable route for developing customized TPU nonwovens suitable for medical, wearable, and filtration applications.