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<p>This review synthesizes research on polylactic acid (PLA) composites incorporating eggshell powder (ESP) as a bio-based filler, with a focus on manufacturing methods, resultant material properties, and emerging patent trends. PLA, a widely adopted biodegradable thermoplastic derived from renewable resources, suffers from inherent brittleness and limited impact resistance, which have motivated extensive research into composite formulations. ESP, derived as an agricultural by-product composed predominantly of calcium carbonate (CaCO₃), has been investigated as an economical and sustainable filler alternative. The reviewed literature demonstrates that the incorporation of ESP into PLA matrices via melt extrusion, injection molding, solvent casting, and additive manufacturing yields complex and method-dependent outcomes. Tensile and flexural strengths are generally enhanced at low filler loadings (5 wt%), while impact strength is consistently reported to decrease as ESP content increases from 0 to 30 wt%. Thermal stability and crystallinity are improved with ESP addition. Surface modification of ESP using fatty acids (propionic and oleic acid) influences filler dispersion and mechanical performance. Antibacterial activity against Staphylococcus aureus and Escherichia coli has been demonstrated in PLA/ESP and related ternary blends. Biodegradation studies indicate that recycled PLA/ESP composites degrade faster than virgin PLA/ESP composites. Analysis of 137 patents reveals growing global interest in PLA/eggshell applications across packaging, tissue engineering, and additive manufacturing domains, with the Patent Cooperation Treaty and the United States accounting for the majority of filings. This review identifies key research gaps and future directions for advancing PLA/ESP composite development.</p>

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Manufacturing methods, properties and patent landscape of polylactic acid eggshell powder composites

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年8月2日

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  • V. Bhuvaneswari,
  • M. Kumar,
  • S. Dhamotharan,
  • M. Sathishkumar

摘要

This review synthesizes research on polylactic acid (PLA) composites incorporating eggshell powder (ESP) as a bio-based filler, with a focus on manufacturing methods, resultant material properties, and emerging patent trends. PLA, a widely adopted biodegradable thermoplastic derived from renewable resources, suffers from inherent brittleness and limited impact resistance, which have motivated extensive research into composite formulations. ESP, derived as an agricultural by-product composed predominantly of calcium carbonate (CaCO₃), has been investigated as an economical and sustainable filler alternative. The reviewed literature demonstrates that the incorporation of ESP into PLA matrices via melt extrusion, injection molding, solvent casting, and additive manufacturing yields complex and method-dependent outcomes. Tensile and flexural strengths are generally enhanced at low filler loadings (5 wt%), while impact strength is consistently reported to decrease as ESP content increases from 0 to 30 wt%. Thermal stability and crystallinity are improved with ESP addition. Surface modification of ESP using fatty acids (propionic and oleic acid) influences filler dispersion and mechanical performance. Antibacterial activity against Staphylococcus aureus and Escherichia coli has been demonstrated in PLA/ESP and related ternary blends. Biodegradation studies indicate that recycled PLA/ESP composites degrade faster than virgin PLA/ESP composites. Analysis of 137 patents reveals growing global interest in PLA/eggshell applications across packaging, tissue engineering, and additive manufacturing domains, with the Patent Cooperation Treaty and the United States accounting for the majority of filings. This review identifies key research gaps and future directions for advancing PLA/ESP composite development.