Impact of Substrate Type on the Properties of Cast Biodegradable Starch-Based Films

Biodegradable films are a viable alternative to conventional plastics, thereby contributing to environmental pollution reduction. This study investigates the impact of substrate type on the properties of starch-based films produced using a plasticizer-assisted casting method. Four different substrates, namely, glass, copper, copper-free laminate, and Teflon®, were evaluated, addressing a research gap in which previous studies primarily focused on film composition. The films were analyzed for color, tensile strength, surface free energy, and surface morphology using optical and electron microscopy. The results demonstrated a substrate-dependent impact on surface properties, particularly optical transparency, surface roughness, and adhesion. The films cast on glass and laminate exhibited higher transparency and lower roughness, while copper substrate induced micro-striations and strong adhesion. Teflon® substrates replicated surface imperfections, which may be advantageous for optical applications, but caused film delamination. Tensile strength did not show statistically significant differences across substrates, although reduced elongation was observed for the films cast on Teflon®. Water vapor permeability was also not significantly affected, indicating a dominant role of bulk material properties. It averaged 25 kg per day per square meter, which means high vapor permeability. Surface free energy analysis revealed marked variations between top and bottom layers, with values ranging from 35 to 70 mJ·m⁻2 depending on the substrate. These findings confirm that the type of casting substrate plays a critical role in determining the surface and optical properties of starch-based films, even at the laboratory scale. This study provides new insights into substrate–film interactions and establishes a foundation for optimizing biodegradable film fabrication for industrial and application-specific needs.