Scalable Continuous Manufacturing Process of Stereocomplex PLA by Twin-Screw Extrusion

A scalable continuous manufacturing method to produce stereocomplex PLA was developed and optimized by melt-blending a 1:1 blend of high molecular weight poly(L-lactide) (PLLA) and high molecular weight poly(D-lactide) (PDLA) in a co-rotating twin-screw extruder. Thermal characteristics of stereocomplex formation were characterized via DSC to identify the optimal temperature profile and time for processing stereocomplex PLA. At the proper temperature window, high stereocomplex formation is achieved as the twin-screw extruder allows for alignment of the chains; this is due to stretching of the polymer chains in the extruder. The extruder processing conditions were optimized and used to produce >95% of stereocomplex PLA conversion (melting peak temperature Tpm = 240 °C). ATR-FTIR depicts the formation of stereocomplex crystallites based on the absorption band at 908 cm−1 (β helix). The only peaks observed for stereocomplex PLA’s WAXD profile were at 2θ values of 12, 21, and 24°, verifying >99% of stereocomplex formation. The total crystallinity of stereocomplex PLA ranges from 56 to 64%. A significant improvement in the tensile behavior was observed in comparison to the homopolymers, resulting in a polymer of high strength and toughness. These results lead us to propose stereocomplex PLA as a potential additive/fiber that can reinforce the material properties of neat PLA.