Advanced Rheological, Dynamic Mechanical and Thermal Characterization of Phase-Separation Behavior of PLA/PCL Blends

This research presents a comprehensive investigation of PLA/PCL polymer blends using advanced rheological characterization, scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and dynamic mechanical, thermal analysis (DMTA) to evaluate phase-separation behavior and functional properties. Polymer composites with various PLA/PCL ratios were fabricated via melt extrusion, a sustainable and scalable approach. The rheological studies revealed significant insights into the blends’ viscoelastic behavior, while SEM analyses provided detailed observations of microstructural phase separation. Thermal transitions and crystallization behaviors were evaluated through DSC, and the dynamic mechanical properties were examined via DMTA. The results confirmed that the tailored PLA/PCL blends exhibit properties suitable for advanced additive manufacturing (AM) and shape memory applications, merging flexibility and environmental sustainability. This study emphasizes the novelty of integrating multidisciplinary characterization methods to unravel the structure–property relationships in PLA/PCL systems. By addressing modern demands for eco-friendly, high-performance materials, this work establishes a foundation for the development of innovative polymer composites with potential applications in smart and responsive technologies.