Taming the Flow with Hyperbranched Polyamides as Melt Modifiers in Polyamide Composites

Abstract Transport equipment manufacturers in the automotive and aerospace industries are focused on developing materials that enhance fuel efficiency and reduce carbon dioxide emissions. A significant approach is employing lightweight materials like aluminum, magnesium, and polymer‐based composites. Polyamide‐based composites, particularly nylon 66, as viable alternatives due to their excellent rigidity, chemical resistance, and thermal stability are investigated to address the limitations of traditional thermosetting resins, which are difficult to recycle and have lengthy molding processes that hinder mass production. This research aims to create a polymer additive that lowers melt viscosity during high‐temperature processing, thereby improving the processability of these composites. Hyperbranched polyamides (HBPs) with a dendritic structure and numerous terminal groups, which offer lower melt viscosity and greater solubility than linear polymers, are synthesized. By disrupting intermolecular bonds within PA66, these HBPs are expected to enhance miscibility and act as internal slip agents and melt‐modifier. Using the A 2 +B 3 approach, novel‐hyperbranched polyamides are produced from commercially available monomers, allowing for better industrial applicability. The resulting composites demonstrate improved dispersion, reduced melt viscosity, and high‐thermal stability, highlighting their potential as effective melt modifiers for engineering plastics in lightweight composite applications.