Exploring the miscibility challenges of bio-based PLA/PBAT backbones in aluminium feedstock for metal material extrusion (MMEX)
In this study, the miscibility challenges and processability of bio-based polylactic acid (PLA)/polybutylene adipate terephthalate (PBAT) blends as a two-component backbone in the binder systems for aluminium (Al) feedstocks in metal material extrusion (MMEX) process were investigated. Differential...
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| Main Authors: | , , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-09-01
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| Series: | Results in Engineering |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590123025027173 |
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| Summary: | In this study, the miscibility challenges and processability of bio-based polylactic acid (PLA)/polybutylene adipate terephthalate (PBAT) blends as a two-component backbone in the binder systems for aluminium (Al) feedstocks in metal material extrusion (MMEX) process were investigated. Differential scanning calorimetry (DSC) and Fourier-transform infrared spectroscopy (FTIR), rheological studies, printability and solvent debinding performance were conducted. DSC and FTIR analyses revealed that the interaction between PLA and PBAT is primarily physical, with minor shifts in the crystallization temperature (Tcc) and melting behaviour influenced by the thermoplastic elastomer (TPE) content as the soluble component in the binder system. Rheological studies showed that PLA/PBAT blends with a lower PLA content exhibited better interphase formation and improved flowability, while higher PLA concentrations led to phase separation and reduced homogeneity. Printability tests demonstrated that increasing PLA content enhanced printing and surface quality, with feedstocks containing 25–30 vol.% PLA achieving defect-free printed parts at higher printing speeds of 40–60 mm/s. However, solvent debinding tests using cyclohexane showed that parts with higher PBAT content maintained structural integrity, while higher PLA content led to increased crack formation, particularly in the outer layers. The results suggest that a careful balance of PLA and PBAT is essential for optimizing feedstock properties for MMEX, with formulations containing 15 vol.% PLA and 25 vol.% PBAT as the backbone and capability of increasing the powder loading to 58 vol.% showing the most promising results for both printability and post-processing stability. |
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| ISSN: | 2590-1230 |