Poly(L-Lactide) (PLA), a fully biobased aliphatic polyester, has attracted significant attention in the last decade due to its exceptional set of properties, such as high tensile modulus/strength, biocompatibility, (bio)degradability in various media, easy recyclability and good melt-state processability by the conventional processes of the plastic/textile industry. Blending PLA with other polymers represents one of the most cost-effective and efficient approaches to develop a next-generation of PLA-based materials with superior properties. In particular, intensive research has been carried out on PLA-based blends with engineering polymers such as polycarbonate (PC), poly(ethylene terephthalate) (PET), poly(butylene terephthalate) (PBT) and various polyamides (PA). This overview, consequently, aims to gather recent works over the last 10 years on these immiscible PLA-based blends processed by melt extrusion, such as twin screw compounding. Furthermore, for a better scientific understanding of various ultimate properties, processing by internal mixers has also been ventured. A specific emphasis on blend morphologies, compatibilization strategies and final (thermo)mechanical properties (tensile/impact strength, ductility and heat deflection temperature) for potential durable and high-performance applications, such as electronic parts (3C parts, electronic cases) to replace PC/ABS blends, has been made.

Bio-based poly(L-lactide)/poly(amide-11) blends (PLA/PA11, 80/20 w/w) and poly(L-lactide)/poly(amide-6) blends (PLA/PA6, 80/20 w/w) are processed by twin-screw extrusion followed by injection-moulding and key rheological parameters controlling their morphologie are investigated. The same work is done using the same PLA modified by a multi-step reactive extrusion route with an epoxy-based chain extender to obtain modified poly(lactide)/poly(amide-11) (PLA-j/PA11 80/20 w/w) blends. The morphologies of the extruded materials and of the injection moulded parts are characterized by SEM and their formation is deeply discussed via rheological investigation to highlight the contribution of viscosity, elasticity and interfacial tension. The existence of a critical shear rate related to the transition from nodular to fibrillar morphology is highlighted and the results are in good agreement with the condition of fibrillation Ca/Ca_(crit) ≥ 4. Interestingly, with the exception of PLA/PA6 specimens, all blends obviously display uniform thin-thread fibrillar morphologies after injection-moulding. Compared with pure PLA, a drastic increase of the ductility was observed in the blends exhibiting a fiberlike structure without meanwhile sacrificing the stiffness. This study confirms that, through the appropriate choice of blend components (viscosity and elasticity ratio, flow conditions, interfacial tensions) the in situ fibrillation concept provides access, at a reasonable cost, to new materials with improved thermomechanical performances, without sacrificing weight and ability to be recycled.