A process
for fabricating biodegradable polymer films from renewable
feedstocks, namely, agar, alginate, and glycerol, with enhanced mechanical
properties has been developed. A critical step in the process involves
use of high shear stress and micromixing in a liquid thin film in
an energy-efficient upsized vortex fluidic device (VFD) operating
under confined-mode conditions. The upsized VFD having a 50 mm-OD
diameter tube titled at 45° requires a fraction of the processing
time and energy consumption relative to the standard VFD having a
20 mm-OD diameter tube titled at the same critical angle. It also
overcomes difficulties of jet feed blockage and excessive gelling
close to the base of the rapidly rotating tube for the high-viscosity
liquid mixture when it is processed in the standard VFD operating
under continuous flow for throughput competitive comparison. The enhanced
mechanical properties of the polymer films (e.g., 0.14 strain) relates
to the formation of a uniform solid inner microstructure and a smoother
surface devoid of porosity. This is in contrast to using conventional
autoclave processing, which affords films with weaker mechanical properties
(e.g., 0.04 strain) having an inner microstructure with cracks and
a rougher surface. In addition, the biodegradability of the polymer
film produced using the upsized VFD (6 days) was not compromised relative
to that produced using conventional autoclave processing. The overall
facile scalable processing in generating a polymer with stronger mechanical
properties is devoid of auxiliary substances and is high in green
chemistry metrics.