A Review on the Transformative Effects of Extrusion Parameters on Poly(Butylene adipate-co-terephthalate)/Poly(Lactic acid) Blends in 3D Printing

Extrusion-based 3D printing stands out as one of the most widespread additive manufacturing techniques, finding applications across engineering and medical sectors, primarily owing to its use of thermoplastic polymers. While poly(lactic acid) (PLA) remains among the most widely used bio-based compostable polymers in material extrusion, its inherent brittleness imposes limitations in sectors requiring more flexible and ductile materials. In this context, the combination of PLA with poly(butylene adipate-co-terephthalate) (PBAT) results in more flexible compostable blends, broadening the scope of advanced applications of 3D-printed parts while upholding sustainability standards. Despite the considerable potential of PLA/PBAT blends, research on their use in material extrusion 3D printing remains limited, highlighting an opportunity for significant advancements in the near future. Therefore, this article provides a detailed review of the influence of printing parameters on the properties of 3D-printed PLA/PBAT blends. It begins with a brief overview of the synthesis methods of PLA and PBAT, and their blend compatibilization strategies, showcasing advancements in the pursuit of versatile and sustainable materials. Furthermore, it also examines potential applications while identifying research gaps that can steer future investigations. In essence, this review not only provides valuable insights for optimizing the printing parameters of these blends in extrusion-based 3D printing but also contributes to the development of more adaptable and sustainable materials, holding substantial promise across various technological domains.