Poly(lactic acid) (PLA), a biodegradable thermoplastic derived from renewable resources, stands out as a substitute to petroleum-based plastics. In spite of its excellent properties, commercial applications are limited because PLA is more expensive and more brittle than traditional petroleum-based resins. PLA can be blended with cellulosic fibers to reduce material cost. However, the lowered cost comes at the expense of flexibility and impact strength, which can be enhanced through the production of microcellular structures in the composite.

Microcellular foaming uses inert gases (e.g., carbon dioxide) as physical blowing agents to make cellular structures with bubble sizes of less than 10 µm and cell-population densities (number of bubbles per unit volume) greater than 10⁹ cells/cm³. These unique characteristics result in a significant increase in toughness and elongation at break (ductility) compared with unfoamed parts because the presence of small bubbles can blunt the crack-tips increasing the energy needed to propagate the crack. Microcellular foams have been produced through a two step batch process. First, large amounts of gas are dissolved in the solid plastic under high pressure (sorption process) to form a single-phase solution. Second, a thermodynamic instability (sudden drop in solubility) triggers cell nucleation and growth as the gas diffuses out of the plastic. Batch production of microcellular PLA has addressed some of the drawbacks of PLA. Unfortunately, the batch foaming process is not likely to be implemented in the industrial production of foams because it is not cost-effective.

This study investigated the continuous microcellular foaming process of PLA and PLA/wood-fiber composites. The effects of the processing temperature and material compositions on the melt viscosity, pressure drop rate, and cell-population density were examined in order to understand the nucleation mechanisms in neat and filled PLA foams. The results indicated that the processing temperature had a strong effect of the rheology of the melt and cell morphology. Processing at a lower temperature significantly increased the cell nucleation rate of neat PLA (amorphous and semi-crystalline) because of the fact that a high melt viscosity induced a high pressure drop rate in the polymer/gas solution. The presence of nanoclay did not affect the homogeneous nucleation but increased the heterogeneous nucleation, allowing both nucleation mechanisms to occur during the foaming process.

The effect of wood-flour (0-30 wt.%) and rheology modifier contents on the melt viscosity and cell morphology of microcellular foamed composites was investigated. The viscosity of the melt increased with wood-flour content and decreased with rheology modifier content, affecting the processing conditions (i.e., pressure drop and pressure drop rate) and foamability of the composites. Matching the viscosity of the composites with that of neat PLA resulted in the best cell morphologies.

Physico-mechanical characterization of microcellular foamed PLA as a function of cell morphology was performed to establish process-morphology-property relationships. The processing variables, i.e., amount of gas injected, flow rate, and processing temperature affected the development of the cellular structure and mechanical properties of the foams.