Flash spinning is a high-efficiency fiber production process that forms both fibers and nonwoven sheets simultaneously by rapidly evaporating a polymer solution using a volatile solvent under high pressure. This review examines the fundamental mechani...
Flash spinning is a high-efficiency fiber production process that forms both fibers and nonwoven sheets simultaneously by rapidly evaporating a polymer solution using a volatile solvent under high pressure. This review examines the fundamental mechanisms of flash spinning and the unique structural characteristics of flash-spun nonwoven fabrics. These materials exhibit excellent mechanical strength, breathability, water resistance, and chemical durability due to their continuous filament structure and high porosity. As a result, flash-spun nonwovens are widely applied in various sectors including medical packaging, protective clothing, construction membranes, industrial filters, and specialty packaging. Despite their advantages, the process faces challenges such as the use of environmentally hazardous solvents, limited material compatibility, and difficulties in quality control. Recent research efforts focus on eco-friendly solvent systems, surface functionalization, process simulation, and the integration of biodegradable or functional polymers. Future developments should aim to enhance sustainability and precision in production, positioning flash spinning as a core platform technology for advanced nonwoven materials. This review provides a comprehensive overview of current research trends, technological advancements, and future prospects in the field of flash-spun nonwovens.