A petroleum-based polymer, isotactic polypropylene (iPP), and a biodegradable polymer, poly(lactic acid) (PLA), were compounded and molded into parts through the micro-injection technique. A systematic structural investigation indicated that the microfibrillation of PLA minor phase depended on the operation parameter of inter-mixer, ie, rotor speed. The higher rotor speed, the lower viscosity ratio of the PLA/iPP pair was favorable for microfibrillation occurred during micro-injection process. The PLA microfibrils with high aspect ratio was successfully introduced into iPP matrix, and the tensile strength and strain at break of iPP/PLA blends were simultaneously improved. This study suggests a promising method for designing special microfibrillar morphology in polymer blend by using conventional melt processing techniques.