Results of the studies dealing with the toughness of polylactic acid/polycaprolactone (PLA/PCL) blends are analyzed with respect to the PCL particle size, PLA matrix crystallinity, and presence of a compatibilizer. It is shown that a high toughness or even “super-toughness” of PLA/PCL blends without a compatibilizer can be achieved for blends with the proper size of PCL particles. Nevertheless, the window for obtaining the super-tough PLA/PCL blends is quite narrow, as the final impact strength is very sensitive to multiple parameters: namely the blend composition, PLA matrix crystallinity, and PCL particle size. Available literature data suggest that the optimal composition for PLA/PCL blends is around 80/20 (w/w). The PLA/PCL(80/20) blends keep high stiffness of PLA matrix and the concentration of PCL particles is sufficient to achieve high toughness. The PLA/PCL(80/20) blends with low-crystallinity PLA matrix (below ca 10%) exhibit the highest toughness for bigger PCL particles (weight average diameter above 1 μm), while the blends with high-crystallinity PLA matrix (above ca 30%) exhibit the highest toughness for smaller PCL particles (weight average diameter below 0.5 μm). The addition of a compatibilizer may improve the toughness only on condition that it helps to achieve a suitable particle size. The toughness of both non-compatibilized and compatibilized PLA/PCL blends with optimized morphology can be more than 15 times higher in comparison with neat PLA.

Poly(lactic acid) (PLA) is a promising material for biomedical applications due to its biodegradability and high stiffness, but suffers from low toughness. We report that blending of PLA with another biodegradable polymer, poly(ε-caprolactone) (PCL), can increase the impact strength above the values of the individual components, while the other important macro- and micromechanical properties remain at well-acceptable level (above the theoretical predictions based on equivalent box model). Although some previous studies indicated incompatibility of PLA and PCL polymers, we demonstrate that the melt-mixing of the polymers with optimized viscosities (PLA/PCL viscosity ratio ∼ 1), the optimized composition (PLA/PCL = 80/20 by weight), and the optimal processing (compression molding with fast cooling) leads to optimal morphology (∼0.6 μm particles of PCL in PLA matrix) and synergistic effect in the mechanical performance of the systems. In an additional set of experiments, we show that the addition of TiO₂ nanoparticles slightly improves stiffness, but significantly reduces the toughness of the resulting nanocomposites. The investigated systems were characterized by electron microscopy (SEM and TEM), notched impact strength, dynamic mechanical analysis, and microindentation hardness testing.