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However, their inherently low melt strength and slow crystallization kinetics hinder the development of high-performance PLA foams. A reinforcement strategy combining in situ fibrillated polytetrafluoroethylene (PTFE) and carbon fibers (CFs) is applied to enhance the morphological, rheological, thermal, mechanical, and foaming behavior of PLA foams fabricated using nitrogen-assisted foam injection molding (FIM). The combined PTFE\/CF reinforcement resulted in uniform cell nucleation and a refined microcellular foam structure. Rheological analysis showed a higher complex viscosity and storage modulus, indicating the formation of a percolated fibrillar network. Notably, extensional viscosity measurements showed that the incorporation of only 0.5 wt % CF induced pronounced strong strain hardening, leading to improved melt strength and foamability. The foam density of composites lowered 15% compared with pure PLA foam. The compressive strength and flexural stiffness improved significantly as compared to pure PLA foams by more than 11% and 20.5%, respectively. Furthermore, the thermal conductivity of the composite foam decreased by 21% with the addition of carbon fiber (CF), indicating improved thermal insulation. These findings demonstrate a promising strategy for developing PLA-based nanocomposite foams for lightweight structural and thermal-insulation applications.<\/jats:p>","DOI":"10.1021\/acs.iecr.6c03418","type":"journal-article","created":{"date-parts":[[2026,9,17]],"date-time":"2026-09-17T08:02:09Z","timestamp":1789632129000},"page":"20482-20493","source":"Crossref","is-referenced-by-count":0,"title":["Nitrogen-Assisted\nFoam Injection Molding of Polylactide\nwith Carbon Fibers and PTFE Nanofibrils"],"prefix":"10.1021","volume":"65","author":[{"ORCID":"https:\/\/orcid.org\/0009-0006-2050-3643","authenticated-orcid":true,"given":"Silla","family":"George Raju","sequence":"first","affiliation":[{"name":"BioMedChem Doctoral School of University of Lodz and Lodz Institute of the Polish Academy of Sciences , 21\/23 Matejki Street , ,","place":["Lodz, Poland, 90-237"]},{"name":"Polish Academy of Sciences , , Sienkiewicza 112 , ,","place":["Lodz, Poland, 90-363"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Valentina","family":"Volpe","sequence":"additional","affiliation":[{"name":"University of Salerno , , Via Giovanni Paolo II 132 , , ,","place":["Fisciano, Salerno, Italy, 84084"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Rita","family":"Salomone","sequence":"additional","affiliation":[{"name":"University of Salerno , , Via Giovanni Paolo II 132 , , ,","place":["Fisciano, Salerno, Italy, 84084"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Hanieh","family":"Kargarzadeh","sequence":"additional","affiliation":[{"name":"Polish Academy of Sciences , , Sienkiewicza 112 , ,","place":["Lodz, Poland, 90-363"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Roberto","family":"Pantani","sequence":"additional","affiliation":[{"name":"University of Salerno , , Via Giovanni Paolo II 132 , , ,","place":["Fisciano, Salerno, Italy, 84084"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-3058-1312","authenticated-orcid":true,"given":"Andrzej","family":"Galeski","sequence":"additional","affiliation":[{"name":"Polish Academy of Sciences , , Sienkiewicza 112 , ,","place":["Lodz, Poland, 90-363"]}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"316","published-online":{"date-parts":[[2026,9,17]]},"reference":[{"issue":"23","key":"2026093007530952300_cit1","doi-asserted-by":"publisher","first-page":"1841","DOI":"10.1002\/1521-4095(200012)12:23%3C1841:AID-ADMA1841%3E3.0.CO;2-E","article-title":"Polylactic acid technology","volume":"12","author":"Drumright","year":"2000","journal-title":"Adv. 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