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<p>Material-extrusion additive manufacturing enables the fabrication of biodegradable polymer components; however, weak interlayer bonding and anisotropic mechanical behavior remain critical limitations affecting the durability of printed structures. In this work, the influence of printing-induced thermal history on interlayer healing, structural evolution, and durability of polybutylene adipate terephthalate (PBAT)-polylactic acid (PLA) biodegradable blends was systematically investigated. PBAT-PLA blends containing 0–40 wt% PBAT were melt compounded, extruded into filaments, and processed via fused filament fabrication. A comprehensive experimental framework integrating rheological, spectroscopic, thermal, structural, and mechanical characterization was employed to establish the process-structure-property relationships governing the performance of the printed materials. Rheological analysis showed that increasing PBAT content reduced melt viscosity from approximately 1250&#xa0;Pa s for neat PLA to ~ 720&#xa0;Pa s for the 30 wt% PBAT blend at 180&#xa0;°C, indicating improved melt flow and printability. Thermal history measurements revealed that the interlayer interface temperature remained above the glass transition region for approximately 5–7&#xa0;s in PBAT-containing blends compared with 3–5&#xa0;s for neat PLA, increasing the diffusion time available for interlayer healing. Structural characterization further showed that PLA exhibited crystallinity in the range of 15–25%, while PBAT-PLA blends displayed reduced crystallinity of 8–18%, suggesting enhanced chain mobility during deposition. Morphological analysis indicated that compatibilization refined PBAT domain size from approximately 4.3 to ~ 2.0&#xa0;μm, leading to improved phase dispersion. The optimized 30 wt% PBAT composition demonstrated healing efficiencies exceeding 0.75, improved weld strength by 60–70%, and reduced wear rate by more than 50% relative to neat PLA. These results establish a thermal-history-dependent process-structure-property framework governing interlayer bonding and durability in PBAT-PLA blends, providing practical guidance for optimizing filament formulations and printing parameters for sustainable additively manufactured components.</p>

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Thermal-history-controlled interlayer healing and durability of material-extruded PBAT-PLA biodegradable blends

  • 期刊论文

  • 发表日期：

    2026年7月14日

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  • Vikram Kedambadi Vasu

摘要

Material-extrusion additive manufacturing enables the fabrication of biodegradable polymer components; however, weak interlayer bonding and anisotropic mechanical behavior remain critical limitations affecting the durability of printed structures. In this work, the influence of printing-induced thermal history on interlayer healing, structural evolution, and durability of polybutylene adipate terephthalate (PBAT)-polylactic acid (PLA) biodegradable blends was systematically investigated. PBAT-PLA blends containing 0–40 wt% PBAT were melt compounded, extruded into filaments, and processed via fused filament fabrication. A comprehensive experimental framework integrating rheological, spectroscopic, thermal, structural, and mechanical characterization was employed to establish the process-structure-property relationships governing the performance of the printed materials. Rheological analysis showed that increasing PBAT content reduced melt viscosity from approximately 1250 Pa s for neat PLA to ~ 720 Pa s for the 30 wt% PBAT blend at 180 °C, indicating improved melt flow and printability. Thermal history measurements revealed that the interlayer interface temperature remained above the glass transition region for approximately 5–7 s in PBAT-containing blends compared with 3–5 s for neat PLA, increasing the diffusion time available for interlayer healing. Structural characterization further showed that PLA exhibited crystallinity in the range of 15–25%, while PBAT-PLA blends displayed reduced crystallinity of 8–18%, suggesting enhanced chain mobility during deposition. Morphological analysis indicated that compatibilization refined PBAT domain size from approximately 4.3 to ~ 2.0 μm, leading to improved phase dispersion. The optimized 30 wt% PBAT composition demonstrated healing efficiencies exceeding 0.75, improved weld strength by 60–70%, and reduced wear rate by more than 50% relative to neat PLA. These results establish a thermal-history-dependent process-structure-property framework governing interlayer bonding and durability in PBAT-PLA blends, providing practical guidance for optimizing filament formulations and printing parameters for sustainable additively manufactured components.