BACKGROUND: The aim of the work presented was to determine the morphology development and relevant change in fibre diameter of a binary polymer blend system during an electrospinning process. The size of the fibre diameter is one of the important factors determining the general properties of non-woven mats formed from electrospun fibres. RESULTS: The morphology and diameter of electrospun polyacrylonitrile (PAN)/poly(methyl methacrylate) (PMMA) blends were investigated as a function of blend ratio using scanning electron microscopy. The diameter of the electrospun PAN/PMMA fibres decreased with increasing PMMA content up to 50 wt%, and then increased again with further increase of PMMA. After thermal treatment, the fibres shrank, and an irregularly shaped morphology was observed. CONCLUSION: The electrospinning of incompatible PAN/PMMA blends leads to a microphase-separation morphology of fibres. A phase inversion occurs at a PMMA content of between 50 and 75 wt%. Due to the phase inversion, the fibre diameter shows a minimum value at the relevant composition. (C) 2008 Society of Chemical Industry