Controlling the morphology and material characteristics of electrospray generated calcium alginate microhydrogels

Electrospraying nano- and micro-particle fabrication is a one-step, non-invasive process, which has application in encapsulating of thermosensitive functional, bioactive materials and cells and making microhydrogels. This study investigates the effect of various electrospraying process parameters on the characteristics of calcium alginate microhydrogel particles. The alginate solution concentration, CaCl2 coagulation bath concentration, voltage, nozzle diameter, distance between nozzle and collecting bath (D), alginate delivery pressure (∼H) were examined. The best droplet formation rate, in non-disperse dripping mode, was obtained at 8 kV using a 500 μm inner diameter nozzle tip, D = 8 cm, H = 20 cm. Morphology, swelling behaviour and texture analysis of the particles which were followed by scanning electron microscopy (SEM) and differential scanning calorimetry (DSC) confirmed that 1.5–2% (w/v) CaCl2 was the desirable concentration for hydrogels formation. Particle size range between 267 and 1500 μm could be obtained by the drip feed mode compared with 2.3–6 μm by the pressure-assisted electrospray through a coaxial head