Ultrasonic Molding of Poly(3-hydroxybutyrate) and Its Clay Nanocomposites: Efficient Microspecimens Production with Minimal Material Loss and Degradation

Ultrasound micromolding (USM) is an emerging processing technology that offers advantages with regard to spatial resolution, material savings, minimum time residence, minimum exposure to high temperatures, and low cost. Recent advances have been focused on nodal point technology, which improves the homogeneity of the molded samples and the repeatability of the properties of processed specimens. The present work demonstrates the suitability of a modified USM technology to process the biodegradable poly(3-hydroxybutyrate) (P3HB), which is a polymer that has well-reported difficulties when processed by conventional methods. Specifically, conventional injection, microinjection, and USM technologies with and without nodal point configurations have been compared. Degradation studies and the evaluation of thermal and mechanical properties confirmed the successful preparation of P3HB microspecimens, maintaining their functional integrity with minimal molecular weight loss. Exfoliated clay structures were observed for P3HB nanocomposites incorporating the C20 and C166 clays and processed by USM. The results highlight the advantages of the modified USM technology, as conventional microinjection failed to produce nanocomposites of P3HB/C116 due to the enhanced degradation caused by C116.