Real Time Monitoring of Morphologic and Mechanical Properties of Polymer Nanocomposites During Extrusion by near Infrared and Ultrasonic Spectroscopy

Extrusion is one of the most applied technologies for the processing of polymer nanocomposites for applications in automotive, electrical and packaging industrial sectors. These nanostructured materials have advantages in comparison to traditional polymer materials, so that properties like tensile strength and modulus, barrier and surface properties, electrical properties and flame retardancy will be improved. There is a need to control amount and dispersion of the nanofillers in the polymer matrix during melt processing and to control the influence of the processing conditions on the nanocomposite formation. For an adequate real time characterization it is necessary to measure directly in the extruder. Spectroscopic methods and Ultrasonic measurements are outstanding methods for this kind of in-line monitoring. This paper deals with the real time determination of the dispersion and the impact strength of polymer nanocomposites in the melt during extrusion by Ultrasonic measurements and NIR spectroscopy. These in-line measurements were correlated with off-line rheological measurements, transmission electron microscopy and mechanical test measurements by multivariate data analysis. The polymers used are polypropylene and polyamide 6. As nanofillers we used different modified layered silicates. We determined the degree of exfoliation as an indicator for the dispersion of the nanofiller in the polymer matrix for different layered silicates and at different process conditions.     

The effect of shear on mechanical properties and orientation of HDPE/mica composites obtained via dynamic packing injection molding (DPIM)

The interfacial interaction and orientation of filler play important roles in the enhancement of mechanical performances for polymer/inorganic filler composites. Shear has been found to be a very effective way for the enhancement of interfacial interaction and orientation. In this work, we will report our recent efforts on exploring the development of microstructure of high density polyethylene (HDPE)/mica composites in the injection‐molded bars obtained by so‐called dynamic packing injection molding (DPIM), which imposed oscillatory shear on the melt during the solidification stage. The mechanical properties were evaluated by tensile testing and dynamic mechanical analysis (DMA), and the crystal morphology, orientation, and the dispersion of mica were characterized by scanning electron microscopy and two‐dimensional wide‐angle X‐ray scattering. Compared with conventional injection molding, DPIM caused an obvious increase in orientation for both HDPE and mica. More importantly, better dispersion and epitaxial crystallization of HDPE was observed on the edge of the mica in the injection‐molded bar. As a result, increased tensile strength and modulus were obtained, accompanied with a decrease of elongation at break. The obtained data were treated by Halpin–Tsai model, and it turned out that this model could be also used to predict the stiffness of oriented polymer/filler composites. Copyright © 2009 John Wiley & Sons, Ltd.     

Bio-Based Nanocomposites of Cellulose Acetate and Nano-Clay with Superior Mechanical Properties

Summary: Bio-based nanocomposites were manufactured by melt intercalation of nanoclays and cellulose acetate (CA) with and without plasticizer. Glycerol triacetate (triacetin) as plasticizer up to 30 mass%, and different types of organo-modified and unmodified montmorillonites (MMTs) as filler were used. X-ray diffraction (XRD), transmission electron microscopy (TEM), and scanning electron microscopy (SEM), were used to study clay dispersion, intercalation/exfoliation, and structure of the composites. XRD and TEM revealed very good dispersion and exfoliation of modified clay throughout the CA matrix. While for unmodified clay agglomeration and poor dispersion but an intercalated structure was observed. The mechanical properties of injection moulded test bars were determined by a tensile experiment giving tensile strength, Young's modulus and elongation at break. Adding plasticizer facilitated the processing and up to 20 mass%, increased the tensile strength, Young's modulus and elongation at break as well. Higher amount of plasticizer diminished the tensile properties except elongation showing a slight increase. In all plasticized composites, organo-modified clay improved the tensile strength and at the same time, young's modulus and elongation almost remained constant. On the other hand, plasticized CA compounded with unmodified clay revealed lower properties. In a particular case, compounding of unplasticized CA with unmodified clay resulted in superior mechanical properties with a novel structure. So that, in optimum percentage –5 mass%- of unmodified clay, tensile strength and young's modulus increased significantly by 335% and 100%, to 178 MPa and 8.4 GPa, respectively. This is a dramatic improvement in strength and stiffness of CA. Adding organo-modified clay resulted in a little improvement in tensile properties. SEM pictures of the optimum composite showed a core/shell structure with high orientation in the shell part. It is supposed that this behaviour is caused by the interaction between CA hydroxyl groups and free cations existing in the galleries of unmodified clay.     

An observation of accelerated exfoliation in iPP/organoclay nanocomposite as induced by repeated shear during melt solidification

A well‐exfoliated morphology is usually observed for polar polymer/clay nanocomposites via dynamic melt processing techniques, whereas only an intercalated or a partially intercalated/partially exfoliated morphology is often obtained for nonpolar polymer/clay nanocomposites, even though some polar compatibilzer is used. In this study, an accelerated exfoliation effect was observed for the first time in iPP/organoclay nanocomposites prepared through so‐called dynamic packing injection molding, in which the specimen is forced to move repeatedly in a chamber by two pistons that move reversibly with the same frequency as the solidification progressively occurs from the mold wall to the molding core part. The disordered level and exfoliated degree of clay was found to dramatically increase from the skin to the core of the prepared samples and eventually the WAXD reflections of interlayer d‐spacing diminished in the core. The changed degree of exfoliation was also proved directly by TEM observation. The prolongation of processing time, the gradual growth of solidification front, the increased melts viscosity, and the shear amplification effect were considered to explain the higher degree of exfoliation in the center zone of mold chamber. Our result suggests that a critical shear force may be needed to break down clay into exfoliated structure. This can be also well used to explain at least partially the intercalated morphology, which is commonly observed for nonpolar polymer/clay nanocomposites via conventional processing. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 2005–2012, 2005     

Preparation and Rheological Characterization of Polymer Nanocomposites Based on Expanded Graphite

A new type of conductive filler, namely expanded graphite (EG), was used to prepare novel nanocomposites. The EG was incorporated into several rather different polymers, specifically polycarbonate (PC), low‐density polyethylene (LDPE), isotactic polypropylene (PP), and polystyrene (PS), using melt mixing in a small‐scale DACA‐Microcompounder. The EG content was varied between 1 and 20 wt%. The rheological properties and morphologies of the nanocomposites were characterized by melt rheology and scanning electron microscopy (SEM), respectively. The melt‐state linear viscoelastic properties were investigated using an ARES rheometer, with the measurements performed in the dynamic mode at various temperatures over a wide range of frequencies. Addition of the EG increased the linear dynamic moduli and melt viscosity of the materials. Up to a certain critical concentration of EG, the materials exhibited a simple liquid‐like behavior. Above this concentration, however, significant changes in the frequency dependences of the moduli and viscosity were observed. In addition, the moduli showed a liquid‐solid transition resulting in a second plateau in the low frequency‐regime, and the complex viscosity revealed shear‐thinning behavior. Specific values of this percolation concentration were found to be at around 4 wt% in the case of PC/EG, 9 wt% for PP/EG and PS/EG, and 12 wt% for PE/EG. This critical concentration was correlated to a network‐like structure formed through interactions between the EG platelets and the polymers. The extent of these complications was found to vary from polymer to polymer, presumably due to different degrees of EG exfoliation and dispersion arising from different EG‐polymer interactions and from variable shearing forces dependent on the polymer viscosities. The formation of network‐like structures is very sensitively displayed using van Gurp‐Palmen plots, which are most suitable for identifying “rheological percolation” in our investigated systems.     

Melt spinning of poly(l/d)lactide 96/4: Effects of molecular weight and melt processing on hydrolytic degradation

This study focused on determining the effects of molecular weight on the degradation of polylactide 96l/4d in melt spinning and the effects of melt processing on hydrolytic degradation. Three polylactides with different inherent viscosities were melt spun, and the fibres were studied in vitro. Results showed that during melt spinning high-molecular-weight polylactide degraded because polymer chains were subject to high shear stress and high melt temperatures, whereas a low-molecular-weight polylactide with low melt viscosity was not affected by melt processing. Most degradation occurred during the melting phase in the length of the extruder barrel. Lactide monomer, generated as the polymer degraded in the melt, significantly affected in vitro degradation such that the degradation rate was directly proportional to the lactide concentration of the polymer.     

DISPERSION AND TENSILE BEHAVIOR OF POLYPROPYLENE/MONTMORILLONITE NANOCOMPOSITES PRODUCED VIA MELT INTERCALATION

Most of the anicles on polymer nanocomposites focus on the importance of chemistry used to modify the surfaceof the clay, usually montmorillonite (MMT), and characterization of the nano-scale structure obtained. The role andimportance of processing were also discussed recently. However, few papers concerning the correlation between morphologyof MMT and mechanical properties were published. In order to understand the tensile behavior of PP/Montmorillonite(MMT) nanocomposites better, and to further improve the reinforcement efficiency, we first prepared the PP nanocompositesvia direct melt intercalation using conventional twin-screw extrusion. The dispersion and tensile property of the compositeswere then investigated by SEM, XRD, TEM and a video-controlled tensile set-up. The macroscopic and microscopicdispersion of MMT in PP matrix was verified by XRD and TEM, combined with SEM. The tensile properties were obtainedby video-controlled tensile set-up, which gives true stress-strain curve. It was found that a partly intercalated and partlyexfoliated structure (also called incomplete exfoliation) existed in the system. Though the tensile strength of PPnanocomposites is not much improved in engineering stress-strain curves, more than 20% increase of true stress was found ina true stress-strain experiment at high true strain, which indicates that only oriented silicate layers can have a big effect ontensile properties. Not only orientation of silicate platelets but also the degree of exfoliation is a key factor to determine thereinforcement efficiency. The reinforcement efficiency of MMT has been discussed based on the "continuum" Halpin-Tsaiequations. A good agreement was found between experimental data and theoretical prediction by changing N value (number of platelets per stack) which corresponding to different state of the dispersion of MMT in PP matrix.     

The effect of organic modifiers with different chain lengths on the dispersion of clay layers in HTPB (hydroxyl terminated polybutadiene)

The series of HTPB (hydroxyl terminated polybutadiene)/organoclay nanocomposite was formed by melt blending with rotationary and revolutionary mixer which generated high shear stress. Organoclays were formed by modifying the pristine clays with organic modifiers which had different hydrophobic chain lengths. As the length of organic modifier increased, the gap size between layers of organoclay became broader. The clays modified with octadecylamine (C18) and dodecyl amine (C12) showed wider gap sizes than that modified with octyl amine (C8). This gap size affected the dispersion state of clays, exfoliation/intercalation in HTPB polymer medium. The mixtures of HTPB with C18 and C12 were transparent without sedimentation and showed almost exfoliated structure. HTPB/C18 mixture showed the higher viscosity and yield strength than HTPB/C12 due to exfoliation. HTPB/C12 showed more elastic behavior than HTPB/C18 mixture because the organoclay C12 had less content of organic modifier.     

The effect of nanoparticle shape on polymer‐nanocomposite rheology and tensile strength

Nanoparticles can influence the properties of polymer materials by a variety of mechanisms. With fullerene, carbon nanotube, and clay or graphene sheet nanocomposites in mind, we investigate how particle shape influences the melt shear viscosity η and the tensile strength τ, which we determine via molecular dynamics simulations. Our simulations of compact (icosahedral), tube or rod‐like, and sheet‐like model nanoparticles, all at a volume fraction ? ≈ 0.05, indicate an order of magnitude increase in the viscosity η relative to the pure melt. This finding evidently can not be explained by continuum hydrodynamics and we provide evidence that the η increase in our model nanocomposites has its origin in chain bridging between the nanoparticles. We find that this increase is the largest for the rod‐like nanoparticles and least for the sheet‐like nanoparticles. Curiously, the enhancements of η and τ exhibit opposite trends with increasing chain length N and with particle shape anisotropy. Evidently, the concept of bridging chains alone cannot account for the increase in τ and we suggest that the deformability or flexibility of the sheet nanoparticles contributes to nanocomposite strength and toughness by reducing the relative value of the Poisson ratio of the composite. The molecular dynamics simulations in the present work focus on the reference case where the modification of the melt structure associated with glass‐formation and entanglement interactions should not be an issue. Since many applications require good particle dispersion, we also focus on the case where the polymer‐particle interactions favor nanoparticle dispersion. Our simulations point to a substantial contribution of nanoparticle shape to both mechanical and processing properties of polymer nanocomposites. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 1882–1897, 2007     

Influences of coupling agent on thermal properties, flammability and mechanical properties of polypropylene/thermoplastic polyurethanes composites filled with expanded graphite

In this study, polypropylene (PP)/thermoplastic polyurethanes (TPU) filled with inorganic intumescent flame retardant expanded graphite (EG) was prepared by melt blending in a twin-screw extruder. The thermal stability, fire retardancy, mechanical properties, and fracture morphology of PP/TPU composites with treated and untreated EG were investigated by thermogravimetric analysis, cone calorimeter, and scanning electron microscope. The results showed that both untreated and treated EG can greatly enhance the thermal stability and fire resistance of polymer matrix materials. Compared with untreated EG, treated EG can further improve the flame retardancy of the composites. For example, treated EG can further reduce the heat release rate, total heat release, and CO emissions of the composites in the combustion. Surface treatment of EG could significantly improve elongation at break and impact strength of PP/TPU/EG composites due to its enhanced interfacial adhesion and the good dispersion of EG particles in the polymer matrix.     

Aqueous Dispersions of Graphene from Electrochemically Exfoliated Graphite

A facile and environmentally friendly synthetic strategy for the production of stable and easily processable dispersions of graphene in water is presented. This strategy represents an alternative to classical chemical exfoliation methods (for example the Hummers method) that are more complex, harmful, and dangerous. The process is based on the electrochemical exfoliation of graphite and includes three simple steps: 1) the anodic exfoliation of graphite in (NH₄)₂SO₄, 2) sonication to separate the oxidized graphene sheets, and 3) reduction of oxidized graphene to graphene. The procedure makes it possible to convert around 30 wt % of the initial graphite into graphene with short processing times and high yields. The graphene sheets are well dispersed in water, have a carbon/oxygen atomic ratio of 11.7, a lateral size of about 0.5–1 μm, and contain only a few graphene layers, most of which are bilayer sheets. The processability of this type of aqueous dispersion has been demonstrated in the fabrication of macroscopic graphene structures, such as graphene aerogels and graphene films, which have been successfully employed as absorbents or as electrodes in supercapacitors, respectively.     

Exfoliation and Noncovalent Functionalization of Graphene Surface with Poly-N-Vinyl-2-Pyrrolidone by In Situ Polymerization

Heteroatom functionalization on a graphene surface can endow the physical and structural properties of graphene. Here, a one-step in situ polymerization method was used for the noncovalent functionalization of a graphene surface with poly-N-vinyl-2-pyrrolidone (PNVP) and the exfoliation of graphite into graphene sheets. The obtained graphene/poly-N-vinyl pyrrolidone (GPNVP) composite was thoroughly characterized. The surface morphology of GPNVP was observed using field emission scanning electron microscopy and high-resolution transmission electron microscopy. Raman spectroscopy and X-ray diffraction studies were carried out to check for the exfoliation of graphite into graphene sheets. Thermogravimetric analysis was performed to calculate the amount of PNVP on the graphene surface in the GPNVP composite. The successful formation of the GPNVP composite and functionalization of the graphene surface was confirmed by various studies. The cyclic voltammetry measurement at different scan rates (5–500 mV/s) and electrochemical impedance spectroscopy study of the GPNVP composite were performed in the typical three-electrode system. The GPNVP composite has excellent rate capability with the capacitive property. This study demonstrates the one-pot preparation of exfoliation and functionalization of a graphene surface with the heterocyclic polymer PNVP; the resulting GPNVP composite will be an ideal candidate for various electrochemical applications.     

Effect of the melt flow index of an HDPE matrix on the properties of composites with wood particles

Composites of wood waste and high-density polyethylene (HDPE) resins and different melt flow index (MFIs) was development in this work. Therefore, it was possible to assess their effect on the mechanical, thermal, and morphologic properties of these composites. The formulations were prepared using a twin-screw extruder, and the MFI, tensile strength, flexural strength, and impact strength of the composites were analyzed. Additionally, the thermal properties were evaluated by differential scanning calorimetry (DSC). Finally, structural analyses using optical microscopy (OM) and scanning electron microscopy (SEM) were performed to assess the particles’ dispersion, distribution, and adhesion to the polymer matrix. The results indicated that composites from HDPE resins with a lower MFI yielded a better dispersion of the wood waste. During processing was observed, reduce the MFI and better dispersion of the polymer matrix, which positively influenced some of the mechanical properties analyzed in the study.     

Nanocomposites by melt intercalation based on polycaprolactone and organoclay

Nanocomposites based on biodegradable polycaprolactone (PCL) and organically modified layered silicates (organoclay) were prepared by melt mixing. Their structures and properties were characterized by wide‐angle X‐ray diffraction, thermal analysis, and rheological measurements. The exfoliation of the organoclay was achieved via a melt mixing process in an internal mixer and showed a dependence on the type of organic modifier, the organoclay contents, and the processing temperature. The addition of the organoclay to PCL increased the crystallization temperature of PCL, but a high content of the organoclay could show an inverse effect. The PCL/organoclay nanocomposites showed a significant enhancement in their mechanical properties and thermal stability due to the exfoliation of the organoclay. The nanocomposites showed a much higher complex viscosity than the neat PCL and significant shear‐thinning behavior in the low frequency range. The shear storage modulus and loss modulus of the nanocomposites also exhibited less frequency dependence than the pure PCL in the low frequency range, and this was caused by the strong interactions between the organoclay layers and PCL molecules and by the good dispersion of exfoliated organoclay platelets in the PCL. © 2003 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 670–678, 2003     

Straightforward synthesis of conductive graphene/polymer nanocomposites from graphite oxide

The reduction of graphite oxide (GO) in the presence of reactive poly(methyl methacrylate) (PMMA), under mild biphasic conditions, directly affords graphene grafted with PMMA. The resulting nanocomposite shows excellent electrical conductivities resulting from the optimal dispersion and exfoliation of graphene in the polymer matrix.     

Shear‐induced clay dispersion in HDPE/PEgMA/organoclay composites as studied via real‐time rheological method

In current study, a real‐time rheological method was used to investigate the intercalation and exfoliation process of clay in high‐density polyethylene/organoclay (HDPE/OMMT) nanocomposites using maleic anhydride grafted polyethylene (PEgMA) as compatibilizer. To do this, a steady shear was applied to the original nonintercalated or slightly intercalated composites prepared via simple mixing. The moduli of the composites were recorded as a function of time. The effect of matrix molecular weight and the content of compatibilizer on the modulus were studied. The role of the compatibilizer is to enhance the interaction between OMMT and polymer matrix, which facilitates the dispersion, intercalation, and exfoliation of OMMT. The matrix molecular weight determines the melt viscosity and affects the shear stress applied to OMMT platelets. Based on the experimental results, different exfoliation processes of OMMT in composites with different matrix molecular weight were demonstrated. The slippage of OMMT layers is suggested in low‐molecular weight matrix, whereas a gradual intercalation process under shear is suggested in high‐molecular weight matrix. Current study demonstrates that real‐time rheological measurement is an effective way to investigate the dispersion, intercalation, and exfoliation of OMMT as well as the structural change of the matrix. Moreover, it also provides a deep understanding for the role of polymer matrix and compatibilizer in the clay intercalation process. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 48: 302–312, 2010     

Effect of exfoliation medium on the morphology of multi-layer graphene oxide and its importance for Poly(Ethylene terephthalate) based nanocomposites

Poly(ethylene terephthalate) (PET)/multi-layer graphene oxide (mGO) nanocomposites were produced using the melt compounding technique, with the aid of a twin-screw extruder. The main goal was to investigate the effect of different exfoliation media on the morphology of graphene oxide and its effects, mainly on the mechanical performance of PET/mGO based polymer nanocomposites. Two different exfoliation media (water and ethanol) were used for the mGO synthesis. Based on each medium, nanocomposites with three different mGO contents (0.05 wt%, 0.1 wt%, and 0.3 wt%) were produced. When exfoliated in water, mGO sheets present larger lateral dimensions, i.e., higher surface area available to interact with polymer chains. All nanocomposites presented similar crystallinity, but with a slight increase related to the neat PET, indicating the nucleating effect of mGO. A theoretical model was used to predict the nanocomposites elastic modulus, justifying the experimental results. The biggest mechanical improvement was presented by a composite with low content of water-exfoliated mGO (0.1 wt%). The polymer tensile strength, strain at break, and toughness were improved by 19%, 238% and 590%, respectively. A significant reduction in the polymer dissipation factor (tanδ) with mGO content was also verified, indicating some confinement of polymeric chains due to interactions with the mGO sheets. The different surface fracture mechanisms presented by the nanocomposite with 0.1 wt% water-exfoliated mGO were verified, in which a good interface allowed greater release of strain energy. The XR-MT data confirmed that differences in mGO morphology can sensitively affect the final composite properties, characterising it as the driving force for mechanical improvements. Therefore, a melt compounded PET/graphene derivative composite is presented, exhibiting more promising results than what is already reported by solution mixed and in-situ polymerised composites. It was possible due to the strategic processing route utilised, in which the exfoliated mGO was pre-mixed with the polymer powder using the SSD technique.     

Functionalized graphene/thermoplastic polyester elastomer nanocomposites by reactive extrusion‐based masterbatch: preparation and properties reinforcement

A reactive extrusion process was developed to fabricate polymer/graphene nanocomposites with good dispersion of graphene sheets in the polymer matrix. The functionalized graphene nanosheet (f‐GNS) activated by diphenylmethane diisocyanate was incorporated in thermoplastic polyester elastomer (TPEE) by reactive extrusion process to produce the TPEE/f‐GNS masterbatch. And then, the TPEE/f‐GNS nanocomposites in different ratios were prepared by masterbatch‐based melt blending. The structure and morphology of functionalized graphene were characterized by Fourier transform infrared, X‐ray photoelectron spectroscopy, X‐ray diffraction and transmission electron microscopy (TEM). The incorporation of f‐GNS significantly improved the mechanical, thermal and crystallization properties of TPEE. With the incorporation of only 0.1 wt% f‐GNS, the tensile strength and elongation at break of nanocomposites were increased by 47.6% and 30.8%, respectively, compared with those of pristine TPEE. Moreover, the degradation temperature for 10 wt% mass loss, storage modulus at ?70°C and crystallization peak temperature (T_cp) of TPEE nanocomposites were consistently improved by 17°C, 7.5% and 36°C. The remarkable reinforcements in mechanical and thermal properties were attributed to the homogeneous dispersion and strong interfacial adhesion of f‐GNS in the TPEE matrix. The functionalization of graphene was beneficial to the improvement of mechanical properties because of the relatively well dispersion of graphene sheets in TPEE matrix, as suggested in the TEM images. This simple and effective approach consisting of chemical functionalization of graphene, reactive extrusion and masterbatch‐based melt blending process is believed to offer possibilities for broadening the graphene applications in the field of polymer processing. Copyright © 2014 John Wiley & Sons, Ltd.     

A facile way to large-scale production of few-layered graphene <Emphasis Type="Italic">via</Emphasis> planetary ball mill

In the field of polymer/graphene nanocomposites, massive production and commercial availability of graphene are essential. Exfoliation of graphite to obtain graphene is one of the most promising ways to large-scale production at extremely low cost. In this work we illustrate a facile strategy for mass production of few-layered (≤ 10) graphene (FLG) via the newly explored ball milling. The achieved FLG concentration was determined by UV/Vis spectroscopy. The formation of FLG was proved by measuring the flake thickness by atomic force microscopy (AFM). Further Raman spectral studies indicated that the crystal structure of exfoliated flakes was preserved satisfactorily during this shear-force dominating process. To increase the maximum concentration obtainable, it’s critical to make a good parameter assessment. N-methylpyrrolidone (NMP) was used as a dispersing medium and the effect of milling parameters was systematically and quantitatively investigated, thus providing a criterion to optimize the milling process. We established the optimal values for solvent volume and initial weight of graphite. As for milling time, the production of FLG was enhanced with continuous milling according to the power law, but not linearly with increasing milling time. Moreover, the possible mechanism involved in milling process was also explored. Our work provides a simple method for graphite exfoliation and has great potential for improving thermal and electrical conductivity of polymer composites in the fields of engineering.     

Cellulose Nanocrystals-mediated Phase Morphology of PLLA/TPU Blends for 3D Printing

Incorporation of nanoparticles into polymer blend to obtain finely dispersed morphology has been considered as an effective strategy to prepare nanocomposites. Owing to the renewable and degradable characters, cellulose nanocrystals(CNCs) have been proposed to tailor the phase morphology of poly(L-lactic acid)(PLLA) blend for producing high-performance fused deposition modeling(FDM) consumables. However,the main challenge associated with the ternary systems is the dispersion of the highly hydrophilic CNCs in non-polar PLLA blend by industrial melt blending without involving solution. Herein, with poly(vinyl acetate)(PVAc) modified CNCs powder(a mixture of PVAc grafted from CNCs and PVAc homopolymer latex), the selective dispersion of CNCs in PLLA has been achieved by simple melt processing of PLLA/TPU(polyether polyurethane)/CNCs blend. This results in the ultra-fine TPU droplets at nanoscale in PLLA and improves the melt processibility of composites in FDM due to the decreased viscosity ratio of the dispersed/matrix and the enhanced melt elasticity of PLLA. Combined with the intensive shear and continuous stretch effect during FDM, aligned TPU nanofibers(TNFs) were in situ formed along the elongational flow direction during deposition, which in turn contributed to the improvement of PLLA/TPU/CNCs with 5 wt% filler loading in tensile ductility by 418%, inter-layer adhesion strength and notched impact toughness by 261% and 210%, respectively, as well as achieved good dimensional accuracy and very fine surface quality.