​​Jan Čmelík and team​

Electrospinning is the most widely used method for producing nanofibres, using high voltage to draw a polymer solution into ultra-fine fibres that solidify almost instantly. But the traditional approach, relying on needle-based systems, has long been held back by persistent problems: clogging, poor throughput, inconsistent fibre formation and limited scalability.

Elmarco developed a needle-free alternative. Instead of forcing polymer through a needle, a stationary wire electrode is coated with a thin polymer film and charged at up to 80 kV. Multiple cones form naturally along the wire, creating stable simultaneous jets across a width of 1.5 to 2 metres. With no mechanical rotation, jet formation remains consistent, producing even nanofibre layers during long production runs. The design also minimises polymer use, reducing solvent volume and evaporation while improving operating costs.

The company has continued refining both the process and its application range. Elmarco's methods can deposit nanofibres directly onto moving yarns and onto a wide variety of substrates, from paper and nonwovens to synthetic fabrics and conductive materials, with configurations tailored to each. Additionally, the team has also worked with biodegradable and biobased materials such as cornstarch films to support more sustainable production options.

Unlocking industrial-scale production

In 2004, Professor Oldřich Jirsák and his team at the Technical University of Liberec (TU Liberec) created the world’s first needle-free electrospinning machine. Elmarco was seeking new opportunities and recognised the potential of the invention. The company established a licence agreement with TU Liberec, granting Elmarco the rights to develop commercial nanofibre production machines.

A working prototype appeared in late 2004, followed by the first industrial line in 2006. By 2008, Elmarco had built a large R&D centre, and in 2010, it introduced its second-generation platform. The company has continued to refine its technology and now has over 280 machines installed in 150 countries, serving sectors ranging from performance apparel to healthcare.

Elmarco’s intellectual property covers the machinery and processes that enable true industrial-scale production. While earlier years saw more patent filings, recent innovations are often incremental, reflecting the maturity of the platform. The company protects its technology in the Czech Republic and in key global markets, and retains a strong connection to academia. Elmarco continues to collaborate closely with TU Liberec, which uses Nanospider™ machines for fundamental research.

About the inventor

Jan Čmelík is the head of the design department and quality assurance at Elmarco. After graduating from the Czech Technical University with a master’s degree in engineering design in 2004, he joined Elmarco in his first professional role. Over nearly two decades, he has grown alongside the company, rising from an engineer to a director. He was instrumental in building the design department and leading the technical iterations that moved electrospinning from a laboratory curiosity to a stable, large-scale industrial process: "Innovation takes time. When we started, even forming a stable jet on an industrial line was a challenge. The lesson is: stay curious and stay patient. Breakthroughs come from persistence."