Influence of chain structure on crystal polymorphism of poly(lactic acid). Part 2. Effect of molecular mass on the crystal growth rate and semicrystalline morphology

Design, clinical applications and post-surgical assessment of bioresorbable 3D-printed craniofacial composite implants

This study details the design, fabrication, clinical trials' evaluation, and analysis after the clinical application of 3D-printed bone reconstruction implants made of nHAp@PLDLLA [nanohydroxyapatite@poly(L-lactide-co-D,L-lactide)] biomaterial. The 3D-printed formulations have been tested as bone reconstruction Cranioimplants in 3 different medical cases, including frontal lobe, mandibular bone, and cleft palate reconstructions. Replacing one of the implants after 6 months provided a unique opportunity to evaluate the post-surgical implant obtained from a human patient. This allowed us to quantify physicochemical changes and develop a spatial map of osseointegration and material degradation kinetics as a function of specific locations. To the best of our knowledge, hydrolytic degradation and variability in the physicochemical and mechanical properties of the biomimetic, 3D-printed implants have not been quantified in the literature after permanent placement in the human body. Such analysis has revealed the constantly changing properties of the implant, which should be considered to optimize the design of patient-specific bone substitutes. Moreover, it has been proven that the obtained composition can produce biomimetic, bioresorbable and bone-forming alloplastic substitutes tailored to each patient, allowing for shorter surgery times and faster patient recovery than currently available methods.

Radial growth rate of near-critical crystal nuclei in poly(l-lactic acid) (PLLA) in Tammann's two-stage development method

The specific features of crystal nucleation widely determine the morphology of the evolving crystalline material. Crystal nucleation is, as a rule, not accessible by direct observation of the nuclei, which develop with time. This limitation is caused by the small size (nanometer scale) of the critical nuclei and the stochastic nature of their formation. We describe an experimental approach to the determination of specific features of the cluster size distribution employing fast scanning calorimetry at scanning rates up to 10 000 K s^-1. The surviving cluster fraction is determined by selectively melting/dissolving clusters smaller than the critical size corresponding to the highest temperature of a short spike positioned between the nucleation and the development stage in Tammann's two-stage method. This approach allows for estimating the time evolution of the radius of the largest detectable clusters in the distribution. Knowing this radius as a function of nucleation time allows for determining a radial growth rate. In the example of poly(l-lactic acid) (PLLA), the order of magnitude estimate of radial growth rates of clusters of about 2-5 nm yields values between 10^-5 and 10^-3 nm s^-1. The radial growth rate of micrometer-sized spherulites is available from optical microscopy. The corresponding values are about three orders of magnitude higher than the values for the nanometer-sized clusters. This difference is explainable by stochastic effects, transient features, and the size dependence of the growth processes on the nanometer scale. The experimental and (order of magnitude) classical nucleation theory estimates agree well.

Parametric Investigation and Optimization to Study the Effect of Process Parameters on the Dimensional Deviation of Fused Deposition Modeling of 3D Printed Parts

Fused deposition modeling (FDM) is the most economical additive manufacturing (AM) technology available for fabricating complex part geometries. However, the involvement of numerous control process parameters and dimensional instabilities are challenges of FDM. Therefore, this study investigated the effect of 3D printing parameters on dimensional deviations, including the length, width, height, and angle of polylactic acid (PLA) printed parts. The selected printing parameters include layer height, number of perimeters, infill density, infill angle, print speed, nozzle temperature, bed temperature, and print orientation. Three-level definitive screening design (DSD) was used to plan experimental runs. The results revealed that infill density is the most consequential parameter for length and width deviation, while layer height is significant for angle and height deviation. The regression models developed for the four responses are non-linear quadratic. The optimal results are obtained considering the integrated approach of desirability and weighted aggregated sum product assessment (WASPAS). The optimal results include a layer height of 0.1 mm, a total of six perimeters, an infill density of 20%, a fill angle of 90°, a print speed of 70 mm/s, a nozzle temperature of 220 °C, a bed temperature of 70 °C, and a print orientation of 90°. The current study provides a guideline to fabricate assistive devices, such as hand and foot orthoses, that require high dimensional accuracies.

Tailoring the Barrier Properties of PLA: A State-of-the-Art Review for Food Packaging Applications

It is now well recognized that the production of petroleum-based packaging materials has created serious ecological problems for the environment due to their resistance to biodegradation. In this context, substantial research efforts have been made to promote the use of biodegradable films as sustainable alternatives to conventionally used packaging materials. Among several biopolymers, poly(lactide) (PLA) has found early application in the food industry thanks to its promising properties and is currently one of the most industrially produced bioplastics. However, more efforts are needed to enhance its performance and expand its applicability in this field, as packaging materials need to meet precise functional requirements such as suitable thermal, mechanical, and gas barrier properties. In particular, improving the mass transfer properties of materials to water vapor, oxygen, and/or carbon dioxide plays a very important role in maintaining food quality and safety, as the rate of typical food degradation reactions (i.e., oxidation, microbial development, and physical reactions) can be greatly reduced. Since most reviews dealing with the properties of PLA have mainly focused on strategies to improve its thermal and mechanical properties, this work aims to review relevant strategies to tailor the barrier properties of PLA-based materials, with the ultimate goal of providing a general guide for the design of PLA-based packaging materials with the desired mass transfer properties.

In-Situ Isothermal Crystallization of Poly(l-lactide)

The isothermal crystallization of poly(l-lactide) (PLLA) has been investigated by in-situ wide angle X-ray diffraction (WAXD) and polarized optical microscopes (POM) equipped with a hot-stage accessory. Results showed that the spherulites of PLLA were formed at high temperature, whereas irregular morphology was observed under a low temperature. This can be attributed to the varying rates of crystallization of PLLA at different temperatures. At low temperatures, the nucleation rate is fast and hence the chains diffuse very slow, resulting in the formation of imperfect crystals. On the other hand, at high temperatures, the nucleation rate is slow and the chains diffuse fast, leading to the formation of perfect crystals. The change in the value of the Avrami exponent with temperature further verifies the varying trend in the morphological feature of the crystals.

Crystallization-Induced Polymer Scaffold Formation in the Polymer/Drug Delivery System Poly(l-lactic acid)/Ethyl Butylacetylaminopropionate (PLLA/IR3535)

Polymer/mosquito-repellent scaffolds exhibit increasing importance in long-lasting human skin protection to be used as wearable devices and allowing for controlled release of repellents. In this study, ethyl butylacetylaminopropionate (IR3535) was used as a human and environmental friendly active mosquito-repellent serving as a solvent to form functional poly(l-lactic acid) (PLLA) scaffolds by crystallization-based solid-liquid thermally induced phase separation. Crystallization of PLLA in the presence of IR3535 is faster than melt-crystallization of neat PLLA, and in the investigated concentration range from 5 to 50 mass % PLLA, its maximum crystallization rate increases with the PLLA content, by both, increases of the maximum crystal growth rate and of the nuclei density. By adjusting the polymer concentration and the crystallization temperature, microporous scaffolds of different fine structures are obtained, hosting the mosquito-repellent in intra- and interspherulitic pores for its intended later evaporation.

Effect of Molar Mass on Critical Specific Work of Flow for Shear-Induced Crystal Nucleation in Poly (l-Lactic Acid)

The concept of specific work of flow has been applied for the analysis of critical shearing conditions for the formation of crystal nuclei in poly (l-lactic acid) (PLLA). Systematic variation in both time and rate of shearing the melt in a parallel-plate rheometer revealed that these parameters are interconvertible regarding the shear-induced formation of crystal nuclei; that is, low shear rate can be compensated for by increasing the shear time and vice versa. This result supports the view that critical shearing conditions can be expressed by a single quantity, providing additional options for tailoring polymer processing routes when enhanced nuclei formation is desired/unwanted. Analysis of PLLA of different mass-average molar masses of 70, 90, 120, and 576 kDa confirmed improved shear-induced crystal nucleation for materials of higher molar mass, with critical specific works of flow, above which shear-induced nuclei formation occurs, of 550, 60, 25, and 5 kPa, respectively.

Equilibrium Melting Temperature of Polymorphic Poly(l-lactide) and Its Supercooling Dependence on Growth Kinetics

In this study, the isothermal crystallization process of poly(l-lactide) (PLLA) has been investigated using in situ XRD, differential scanning calorimetry (DSC), and polarized optical microscopy (POM). Linear and nonlinear extrapolation methods have been deployed to estimate the equilibrium melting temperature (Tm0), which is used for analyzing the supercooling dependence of the PLLA spherulitic growth rate (G). A double-melting behavior observed for PLLA under crystallization T_c < 120 °C has been attributed to the formation of both α′ and α crystals. The Tm0 values of both α′ and α crystals have been evaluated using the linear method (172.8 °C) and nonlinear method (196.4 °C), with the nonlinear estimate being 23.6 °C higher. A discontinuity in the temperature dependence of spherulite growth rate is observed around 128.3 °C. Regime II–III transition is found to occur at 128.3 °C when Tm0 = 196.4 °C as estimated by the nonlinear extrapolation method.