The unique geometry of hollow fibers provides high surface area and internal channels for fluid transport, making them attractive across several applications, including water purification, medical devices, pharmaceutical development, energy conversion, and functional textiles. Spinning methods that operate at low cost and high throughput while being environmentally sustainable are of industrial interest. Segmented arc melt spinning provides a scalable and solvent-free approach to producing hollow fibers. In this process, a polymer melt is extruded through a die composed of arced segments, creating multiple polymer streams that coalesce further down the spin line to form a single hollow fiber. It is observed that under certain spinning conditions, fibers may develop non-circular cross-sections or fail to retain hollowness, which limits their performance in the target application. This fiber formation process is highly dependent on the rheological properties of the polymer melt, which are influenced by the selected processing parameters and polymer feedstock.
In this study, we aim to connect the viscoelastic properties of the polymer melt to the resulting formation and geometry of hollow fibers during the segmented arc melt spinning process. Fibers are spun using a die with three segmented arcs, and the spinning parameters of temperature, mass throughput, and quench air speed are systematically varied. Increasing mass throughput at constant die geometry raises the shear rate in the extrusion channel, leading to higher normal forces which impact die swell and increase fiber hollowness. Polymer solidification also influences spinnability and fiber geometry, as high quench air settings or low spinning temperatures lead to incomplete coalescence of the polymer segments and non-circular fiber cross-sections. Polypropylene is used as a model polymer to examine the effects of molecular weight distribution on hollow fiber spinning. We investigate two methods for tailoring the molecular weight distribution: blending commercial spinning grades of polypropylene with varied molecular weights and controlled degradation through the addition of organic peroxide. Dynamic oscillatory shear rheology is used to extract the characteristics of polymer melts, such as relaxation time at the spinning conditions of interest. The dimensionless Weissenberg number is used to correlate the rheological and spinning parameters to the fiber geometry. In addition, we explore the visualization of the fiber formation process through high-speed imaging near the spinneret to extract the segment coalescence length and polymer stream deflection and their relation to viscoelastic polymer properties. By understanding the relationship between polymer and spinning properties to fiber formation and geometry, this research enables easier commercialization of low-cost hollow fibers for functional applications.