Near-Field Electrospinning as a Project-Based Learning Tool Through Low-Cost 3D Printer Modification

Abstract

Project-based learning has proven to be an effective strategy for developing technical and analytical competencies in engineering education, particularly when students are exposed to real-world systems that integrate multiple disciplines. In this work, a hands-on educational project is presented in which undergraduate engineering students modified a low-cost Cartesian 3D printer to explore the fundamentals of Near-Field Electrospinning (NFES), an advanced manufacturing technique typically restricted to specialized research laboratories. The project was designed to promote active learning through system adaptation, experimental setup, and parameter exploration, allowing students to engage with concepts related to electrostatics, fluid behavior, motion control, and process integration. Rather than focusing on performance optimization, the activity emphasized understanding the relationships between processing conditions and physical outcomes, as well as the development of problem-solving and troubleshooting skills. As part of the learning experience, the adapted system was experimentally validated through qualitative fiber deposition tests using a syringe-based extrusion system and controlled motion paths. Optical microscopy and scanning electron microscopy (SEM) were used as instructional tools to visualize fiber formation and morphology, reinforcing theoretical concepts discussed during the course. The results indicate that adapting accessible fabrication platforms to demonstrate advanced manufacturing techniques can significantly enhance student engagement and conceptual understanding. This approach offers a replicable, low-cost framework for integrating complex engineering processes into educational environments, thereby bridging the gap between theory and practice.