Abstract In the electrospinning process submicron‐diameter polymer fibers can be produced when a high potential difference is applied to a polymer drop suspended at the tip of a capillary. The electrospinning process is affected by a wide range of parameters, because of which controlling the properties of the fibers is difficult. This is the major hurdle in the development of practical applications of electrospun fibers along with its low productivity. Here we are proposing to use the electric current in the electrospinning process to control the “quality of the fibers”. Electrospinning of a solution of polyacrylonitrile in dimethylformamide (PAN/DMF) was done by applying a programmed variable flow rate at different constant voltages. The electric current in the process was measured in real time. Four types of jet regimes were observed, electric current and the morphology of the fibers corresponding to these regimes were analyzed. A relation between the electric current, type of jet and morphology of the fibers has been established. The mechanical properties of electrospun fiber mats were also measured by a tensile testing method. POLYM. ENG. SCI. 46:954–959, 2006. © 2006 Society of Plastics Engineers