
doi: 10.1002/adts.70461
ABSTRACT Melt‐electrospinning (MES) direct writing enables the deposition of polymer fibers in predefined patterns and is a critical step toward fabricating three‐dimensional scaffolds for tissue engineering. While a predictive theoretical model for MES has been developed and experimentally validated for stationary spinning configurations, its capability to simulate direct writing scenarios involving arbitrary nozzle trajectories at varying feed rates has not been demonstrated. In this study, the validated model is applied to simulate two direct writing cases: deposition of a complex geometry (MFCL@UofA image) and a rectangular path at nozzle feed rates ranging from 500 mm/min to 100000 mm/min. For the complex geometry, the simulation reproduces the macro‐level pattern with reasonable qualitative correspondence to the experimentally direct‐written result. For the feed rate study, simulation and experiment are in qualitative agreement across all four experimentally accessible feed rates, both confirming the progressive transition from densely coiled fiber accumulation at low speeds to stretched, aligned deposition at high speeds. Simulation at feed rates exceeding the printer hardware limit further predicts corner momentum effects consistent with expected physical behavior. These results establish the predictive model as a viable tool for design‐space exploration in MES direct writing applications.
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