Bottom-Up Development of Nanoimprinted PLLA Composite Films with Enhanced Antibacterial Properties for Smart Packaging Applications

In this work, polymer nanocomposite films based on poly(L-lactic acid) (PLLA) were reinforced with mesoporous silica nanoparticles, mesoporous cellular foam (MCF) and Santa Barbara amorphous-15 (SBA). PLLA is a biobased aliphatic polyester, that possesses excellent thermomechanical properties, and has already been commercialized for packaging applications. The aim was to utilize nanoparticles that have already been established as nanocarriers to enhance the mechanical and thermal properties of PLLA. Since the introduction of antibacterial properties has become an emerging trend in packaging applications, to achieve an effective antimicrobial activity, micro/nano 3D micropillars decorated with cone- and needle-shaped nanostructures were implemented on the surface of the films by means of thermal nanoimprint lithography (t-NIL), a novel and feasible fabrication technique with multiple industrial applications. The materials were characterized regarding their composition and crystallinity using Fourier transform infrared spectroscopy (FT-IR) and X-ray diffraction (XRD), respectively, and their thermal properties using differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Their mechanical properties were examined by the nanoindentation technique, while the films’ antimicrobial activity against the bacteria Escherichia coli and Staphylococcus aureus strains was tested in vitro. The results demonstrated the successful production of nanocomposite PLLA films, which exhibited improved mechanical and thermal properties compared to the pristine material, as well as notable antibacterial activity, setting new groundwork for the potential development of biobased smart packaging materials.