Tailoring the Performance Profiles of Polycarbonate-Based Engineering Blends Through Formulation and Compatibilization

Polycarbonate (PC)-based engineering blends were investigated to determine how formulation design and compatibilizer addition influence their mechanical, thermal, thermomechanical, and morphological characteristics. The study was conducted in three stages. First, PC was blended separately with acrylonitrile–butadiene–styrene (ABS), acrylonitrile–styrene–acrylate (ASA), and styrene–butadiene–styrene (SBS) over a range of compositions to compare their effects on mechanical performance. A representative PC/ASA formulation was then selected to evaluate the effect of maleic anhydride-grafted ABS (ABS-g-MAH). Finally, poly(methyl methacrylate) (PMMA) was incorporated into the selected PC/ASA formulation to form a ternary PC/ASA/PMMA system, in which the effect of ABS-g-MAH was further examined. Component identity and loading produced distinct mechanical trade-offs: ABS and ASA progressively reduced strength, stiffness, and elongation at break, whereas SBS better preserved tensile deformation capacity and flexural strength despite reduced stiffness. ABS-g-MAH substantially enhanced ductility and impact resistance in both selected systems, while its effects on stiffness, dynamic mechanical behavior, and thermal properties depended on blend composition and loading. Selective-etching scanning electron microscopy further revealed finer and more uniformly distributed phase morphologies after ABS-g-MAH addition. Overall, the results demonstrate that component selection establishes the underlying performance profile of PC-based blends, while compatibilizer addition provides a further means of adjusting morphology and property balance in a formulation-dependent manner. These findings provide a practical framework for tailoring PC-based engineering blends toward different performance requirements.