Development of talc-filled PBAT/PLA and PBSA/PBAT binary blend films: Effects of multilayer architecture and uniaxial orientation on performance

This study developed PBAT-based biodegradable blend films using PLA or PBSA in mono- and tri-layer configurations with talc reinforcement, processed via blown film extrusion and further enhanced through uniaxial stretching. The films were systematically evaluated for mechanical, barrier, optical, and structural performance to benchmark against commercial biodegradable packaging materials. PBAT–PLA systems demonstrated superior stiffness and strength compared to PBSA–PBAT, with multilayer structures outperforming monolayers. Uniaxial stretching significantly enhanced mechanical and barrier properties due to polymer chain orientation and strain-induced crystallization, as supported by thermal analysis. Multilayer structures also improved UV shielding, while stretching reduced light transmittance. Overall, this work present a strategy for engineering high-performance biodegradable packaging films through blend design, multilayer structuring, and controlled orientation.