This study develops highly flexible, biodegradable polymer blends using bio-based polyhydroxyalkanoate (PHA) polymers for Fused Deposition Modeling (FDM) 3D printing. A Design of Experiment (DoE) approach optimized blend compositions by varying crystallinity levels of three PHAs, processed via twin-screw extrusion. Rheological analysis revealed that PHA blends exhibited 30–50% lower viscosity than PLA at low shear rates, ensuring improved processability. Tensile testing confirmed favorable mechanical properties, with elongation at break exceeding 2000%, significantly surpassing PLA (29%). Differential scanning calorimetry (DSC) indicated partial miscibility and crystallinity reductions of up to 50%, influencing printability. Optimized 3D printing parameters demonstrated minimal warping for blends with crystallinity below 18%, ensuring high-dimensional stability. During home composting tests, PHA blends showed significant degradation within two months, whereas PLA remained intact. Scanning electron microscopy (SEM) confirmed microbial degradation. Cytotoxicity tests demonstrated that the blends were non-toxic, supporting applications in tissue engineering. These findings highlight the potential of PHA-based blends as sustainable, high-performance materials for biomedical, packaging, and environmental applications.

The work is focused on the study of the influence of different types of inorganic fillers, in combination with modifiers, on the rheological, thermal, and mechanical properties of a biodegradable mixture based on PLA/PHB. Ten types of inorganic fillers based on talc, magnesium hydroxide, aluminum hydroxide, calcium carbonate, and silicon dioxide were used in the study, along with three types of modifiers. It was concluded that fillers containing reactive OH groups on their surface act as strong pro-degradants in PLA/PHB blends, and their degrading effect can be suppressed by the addition of reactive modifiers. Each modifier acts specifically with different types of fillers. Therefore, it is necessary to select a suitable filler/modifier combination not only for fillers with different chemical compositions but also for fillers with different morphologies within the same chemical type. Moreover, the preparation of PLA/PHB/magnesium hydroxide blends with suitable processing and application properties opens the possibility of developing environmentally friendly polymeric materials with a reduced flammability. The addition of talc, which has a platelet structure, can increase the barrier properties of the mixture.

Mechanical recycling of polyethylene terephthalate (PET) is a key strategy for circular packaging applications; however, repeated thermo-mechanical processing leads to progressive polymer degradation. In this study, the effect of controlled repeated extrusion on the degradation behavior of bottle-grade PET was systematically investigated under laboratory conditions. Mechanical recycling was simulated using a co-rotating twin-screw extruder, where PET was subjected to up to four consecutive processing cycles corresponding to a cumulative residence time of 8 min. Progressive processing resulted in chain scission, reflected by a decrease in intrinsic viscosity from approximately 0.80 to 0.65 dL·g⁻¹ and a corresponding reduction in molecular weight. Melt flow rate increased accordingly, indicating a gradual loss of melt strength. Differential scanning calorimetry revealed that the glass transition and melting temperatures remained nearly unchanged, while the degree of crystallinity increased from approximately 23.0% to 29.5%, accompanied by changes in crystallization behavior. These structural changes led to reduced ductility, with elongation at break decreasing from about 84% to 60%. Optical analysis showed systematic material darkening, and a strong linear correlation between lightness (L*) and intrinsic viscosity was observed. By isolating intrinsic thermo-mechanical degradation effects under controlled processing conditions, this study enables a clearer definition of realistic reuse limits for mechanically recycled bottle-grade PET. The results indicate that bottle-grade PET retains properties compatible with demanding applications only after a limited number of thermo-mechanical processing cycles, whereas further processing restricts its usability to less demanding applications such as fibers, films, and non-food packaging.

This study develops highly flexible, biodegradable polymer blends using bio-based polyhydroxyalkanoate (PHA) polymers for Fused Deposition Modeling (FDM) 3D printing. A Design of Experiments (DoE) approach optimized blend compositions by varying crystallinity levels of three PHAs, processed via twin-screw extrusion. Rheological analysis revealed that PHA blends exhibited 30–50% lower viscosity than PLA at low shear rates, ensuring improved processability. Tensile testing confirmed favorable mechanical properties, with elongation at break exceeding 2000%, significantly surpassing PLA (29%). Differential Scanning Calorimetry (DSC) indicated partial miscibility and crystallinity reductions of up to 50%, influencing printability. Optimized 3D printing parameters demonstrated minimal warping for blends with crystallinity below 18%, ensuring high-dimensional stability. In home-composting tests, PHA blends showed significant degradation within two months, whereas PLA remained intact. Scanning Electron Microscopy (SEM) confirmed microbial degradation. Cytotoxicity tests demonstrated that the blends were non-toxic, supporting applications in tissue engineering. These findings highlight the potential of PHA-based blends as sustainable, high-performance materials for biomedical, packaging, and environmental applications.

This study examines binary blends of three types of polyhydroxyalkanoates (PHAs)—poly(3-hydroxybutyrate) (PHB), poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBH), and poly(3-hydroxybutyrate-co-4-hydroxybutyrate) (P3HB4HB)—with a focus on their rheological, thermal, and mechanical behavior. The blends exhibit partial miscibility in both the melt and solid states. Glass transition analysis revealed that semicrystalline/amorphous PHA combinations are fully miscible (single Tg) at amorphous PHA contents below 30 wt%. Above this threshold, a two-phase morphology develops, consisting of crystalline spherulites embedded in an amorphous matrix. When the amorphous PHA content reached ≥30 wt%, the blends could be oriented by stretching, yielding materials that display thermoplastic elastomer (TPE)-like behavior without chemical modification of the base polymers. Thermal and mechanical characterization, supported by X-ray diffraction of samples before and after orientation, confirmed that the elastomeric properties originate from the multiphase architecture formed by crystalline and amorphous domains interconnected through a miscible amorphous fraction.