Modified Polylactic Acid with Improved Impact Resistance in the Presence of a Thermoplastic Elastomer and the Influence of Fused Filament Fabrication on Its Physical Properties

The standard polylactic acid (PLA), as a biodegradable thermoplastic polymer, is commonly used in various industrial sectors, food, and medical fields. Unfortunately, it is characterized by a low elongation at break and low impact energy. In this study, a thermoplastic copolyester elastomer (TPCE) was added at different weight ratios to improve the impact resistance of PLA. DSC analysis revealed that the two polymers were immiscible. A good balance of impact resistance and rigidity was reached using the formulation that was composed of 80% PLA and 20% TPCE, with an elongation at break of 155% compared to 4% for neat PLA. This new formulation was selected to be tested in a fused filament fabrication process. The influence of the nozzle and bed temperatures as printing parameters on the mechanical and thermal properties was explored. Better impact resistance was observed with the increase in the two thermal printing parameters. The crystallinity degree was not influenced by the variation in the nozzle temperature. However, it was increased at higher bed temperatures. Tomographic observations showed an anisotropic distribution of the porosity, where it was mostly present between the adjacent printed filaments and it was reduced with the increase in the nozzle and bed temperatures.