The Magic of Melt Blown Process: 3 Surprising Facts You Need to Know

Melt Blown Process

Melt blown process is a method of producing microfibers used in a wide range of industries, from medical masks to air filters. But do you know how this process works? In this article, we’ll delve into the details of melt blown process and reveal some surprising facts that you might not have known before.

Sure! When I refer to “The Magic” of melt blown process, I’m talking about the incredible properties and capabilities of the microfibers produced by this technique.

Firstly, melt blown process can create fibers with a diameter of less than 1 micron, which is significantly smaller than the diameter of a human hair. This ultra-fine size makes melt blown fibers ideal for producing high-quality filtration materials that can capture even the smallest particles.

In addition, melt blown fibers have a high surface area to volume ratio, which means that they can hold a large amount of material relative to their size. This property makes them useful for a wide range of applications, from insulation to battery separators.

Finally, melt blown process is incredibly versatile and can be used to produce materials with a wide range of properties. By adjusting the type of polymer used and the process parameters, manufacturers can create materials that are strong, flexible, heat-resistant, and more.

Overall, the “magic” of melt blown process lies in its ability to produce microfibers with exceptional properties and versatility, making it an essential technique in many industries.

The Basics of Melt Blown Process

Melt blown process is a technique used to create non-woven fabrics by melting and extruding polymer resins. The process involves heating the polymer to a high temperature and then forcing it through small nozzles to create fine fibers. These fibers are then collected on a conveyor belt or drum and bonded together to form a web of material.

One key advantage of melt blown process is that it can produce fibers with a diameter of less than 1 micron. This makes it ideal for producing high-quality filtration materials that can capture even the smallest particles.learn more(wikipedia)

Surprising Fact #1: MeltBlown Process was Invented by Accident

Believe it or not, melt blown process was invented by accident! In the 1950s, a researcher at the Naval Research Laboratory was experimenting with different methods of producing ultra-fine fibers. One day, he accidentally left a polymer resin near a hot plate, and when he returned, he discovered that the resin had melted and formed fine fibers. This serendipitous discovery led to the development of melt blown process as we know it today.

Surprising Fact #2: MeltBlown Process is Essential for Medical Masks

During the COVID-19 pandemic, medical masks have become an essential item for protecting ourselves and others from the virus. But did you know that melt blown process is a crucial component of medical masks? The melt blown fabric in the middle layer of the mask is responsible for filtering out harmful particles, including the virus that causes COVID-19.

Surprising Fact #3: MeltBlown Process is Used in a Variety of Industries

While melt blown process is most commonly associated with filtration materials and medical masks, it has a wide range of other applications as well. For example, it’s used to produce insulation for buildings and clothing, as well as sound-absorbing materials for cars and airplanes. It’s also used in the production of battery separators, which are essential for many types of batteries.


Melt blown process may not be a household name, but it plays a crucial role in many industries and products that we rely on every day. Whether you’re wearing a medical mask or sitting in a soundproofed room, you can thank melt blown process for making it possible.


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