High Shear Mixer Research Articles

Sustainable graphene production for solution-processed microsupercapacitors and multipurpose flexible electronics

The growing demand for portable and wearable electronics, Internet of Things microdevices, and wireless sensor networks has led to the development of miniaturized energy storage devices, such as microsupercapacitors (mSCs). With excellent electrical conductivity and high surface area in a layered structure, graphene materials are ideal for mSCs, but current manufacturing methods still hinder their widespread integration. Here, we propose a sustainable approach for the rapid and eco-friendly production of few-layer graphene flakes based on the exfoliation of graphite in water by a combination of high-shear mixing and a high-pressure airless spray. An all-carbon composite paste with high electrical conductivity and tunable viscosity was designed to fabricate planar, interdigitated mSCs on polyethylene terephthalate (PET). The flexible, metal-free mSCs achieved a Coulombic efficiency close to 100%, with areal and volumetric capacitances of 6.16 mF cm−2 and 2.46 F cm−3, respectively. The maximum energy density exceeds 200 μWh cm−3 with 91.5% capacitance retention after 10000 galvanostatic chargedischarge cycles. The mSCs retain the same performance when subjected to a wide bending range and can be easily modularized to adjust the voltage and capacitance outputs. Finally, high-performance coatings for electromagnetic interference shielding and wearable strain sensors are also fabricated to demonstrate the multipurpose applicability of the graphene-based paste.

Life Cycle Assessment for the Use of Waste Plastics in Asphalt Concrete Mixes

Improper waste disposal poses the risk of contaminating natural water bodies and soil. The low recycling rate of plastics and their fate in landfills are significant global environmental concerns. Efforts to increase the use of recycled plastics worldwide aim to address the hazardous consequences of improper plastic treatment. One potential solution is incorporating plastics as binder or mixture modifiers in asphalt concrete (AC) mixtures, which repurposes waste plastics while reducing environmental impacts related to AC production. This study calculated the environmental impacts of repurposing waste plastics, specifically low-density polyethylene and polystyrene, into modifiers in AC mixes. Wet and dry processes were considered. The environmental impacts of plastic-modified AC mixes were compared with those of styrene-butadiene-styrene (SBS)-modified mixes. The life cycle assessment covered the following processes: (1) collection, sorting, and shredding of waste plastics; (2) transportation of waste plastics from landfill to recycling facility and then to the asphalt plant; (3) supply and transportation of virgin materials; (4) production of AC mixtures; (5) transport of material and equipment to site; and (6) onsite operations. The study concluded that waste plastic-modified mixes outperformed SBS-modified mixtures with regard to environmental performance, except for ozone depletion resulting from certain recycling process activities. The high-shear mixing in the wet process had a significant impact. Sensitivity analyses revealed the influence of binder content and material transportation on the overall environmental assessment.

Quaternary blended eco high performance concrete utilizing high volumes of siliceous additives

This research examines the optimal feasibility of incorporating siliceous additives as an adjunct material for cement in the formulation of environmentally sustainable high-performance concrete (Eco-HPC). Siliceous materials, including Nano silica (NS), Rice Husk Ash (RHA), and Fly Ash (FA), were fine-tuned within the cementitious system in order to achieve the amplified performance of Eco-HPC by reducing the required cement content from 370 kg/m3 to 273 kg/m3. This is achieved by employing the Modified Andreasen and Andreasen (MA&A) particle packing model, with ‘q’ (distribution factor) as ‘0.3’. The Levenberg Marquardt algorithm (curve fitting) was utilized to validate the packing density of each concrete blends. Initially, the dry NS agglomerates are synthesized into stabilized aqueous dispersion through High shear mixing (10 min/1750 rpm) followed by probe sonication (15 min/(1/3) s/s) with anionic surfactant dosage of 0.1 g/10 g. Incorporating secondary siliceous binders into the cement matrix led to an enhancement in the packing density, increasing from 0.94 (nullary) to 0.96 (quaternary) which in turn alters the reactivity and cohesiveness of the matrix. Compressive strength values for Binary (NS2), Ternary (RN15, FN20), and quaternary mix (FRN25) were observed as 57.42 MPa, 56.83 MPa, 55.34 MPa, and 52.58 MPa, respectively, for primary binder contents of 362 kg/m3, 314 kg/m3, 296 kg/m3, and 273 kg/m3 without compromising durability parameters. An assessment on reduced carbon dioxide emissions indicated that increasing the cement replacement percentages in Eco-HPC by up to 30% for binder contents of 358 kg/m3, 296 kg/m3, 259 kg/m3, and 273 kg/m3 resulted in a reduction of CO2 emissions by 2.98%, 18%, 27%, and 23.33%, respectively. Among the twelve formulated mixes, FRN25, FRN20, FRN15 and FN30 are identified as Eco-HPC mix through a computational framework which integrates the packing density, carbon emission, strength and diffusion coefficient.

Development and Evaluation of a Water-Free In Situ Depot Gel Formulation for Long-Acting and Stable Delivery of Peptide Drug ACTY116.

In situ depot gel is a type of polymeric long-acting injectable (pLAI) drug delivery system; compared to microsphere technology, its preparation process is simpler and more conducive to industrialization. To ensure the chemical stability of peptide ACTY116, we avoided the use of harsh conditions such as high temperatures, high shear mixing, or homogenization; maintaining a water-free and oxygen-free environment was also critical to prevent hydrolysis and oxidation. Molecular dynamics (MDs) simulations were employed to assess the stability mechanism between ACTY116 and the pLAI system. The initial structure of ACTY116 with an alpha helix conformation was constructed using SYBYL-X, and the copolymer PLGA was generated by AMBER 16; results showed that PLGA-based in situ depot gel improved conformational stability of ACTY116 through hydrogen bonds formed between peptide ACTY116 and the components of the pLAI formulation, while PLGA (Poly(DL-lactide-co-glycolide)) also created steric hindrance and shielding effects to prevent conformational changes. As a result, the chemical and conformational stability and in vivo long-acting characteristics of ACTY116 ensure its enhanced efficacy. In summary, we successfully achieved our objective of developing a highly stable peptide-loaded long-acting injectable (LAI) in situ depot gel formulation that is stable for at least 3 months under harsh conditions (40 °C, above body temperature), elucidating the underlying stabilisation mechanism, and the high stability of the ACTY116 pLAI formulation creates favourable conditions for its in vivo pharmacological activity lasting for weeks or even months.

Laboratory Evaluation of Storage Stability for Asphalt Binder Modified with Crumb Rubber and Styrene-Isoprene-Styrene Depending on Evaluation Factors and Blending Condition.

Modified asphalt binders are still considered important in asphalt pavement. However, the comprehensive use of various modifiers is limited due to storage stability issues. Moreover, there is a scarcity of detailed analyses regarding the degree of separation for asphalt binders among each method despite the utilization of various methods to assess the storage stability of binders. Therefore, a comprehensive analysis was conducted to assess the storage stability of asphalt binder modified with a crumb rubber modifier (CRM) and styrene-isoprene-styrene (SIS), utilizing five evaluation factors following the ASTM D7173 guidelines based on four mixing methods (A: high-shear mixing method, B: low-speed agitating method, C: high-shear mixing method + low mixing method, D: low-speed agitating method + low mixing method). To produce the modified asphalt binder, the proportions of the CRM were 5% and 10% for each binder, and 10% SIS was added to all binders. The results in this study convey that (1) the addition of the modifier led to an increase in G*/sin δ with different mixing methods, but using mixing methods (C and D) for a relatively long time resulted in a lower G*/sin δ, indicating suboptimal performance; (2) through the multiple stress creep recovery (MSCR), rheological properties of Jnr and % rec exhibited trends similar to G*/sin δ evaluation, highlighting an improved elastic recovery with a higher modifier content; (3) storage stability assessment revealed consistent trends in high-shear mixing groups (A and C), while low-speed mixing groups (B and D) exhibited an elevated separation index (SI), suggesting a sensitivity to modification conditions; (4) evaluation using the MSCR method indicated that % rec with a 3.2 kPa load is effective for the sensitive assessment of binder storage stability and Jnr showed a limited sensitivity across varying loads, advocating for % rec for precise evaluation; and (5) despite permitting various tests, achieving consistent results remains challenging. Future research should explore diverse modifiers and optimal evaluation methods to enhance knowledge of binder behavior and separation dynamics.

Investigating hydrodynamic cavitation as an efficient means for removal of per- and polyfluoroalkyl substances from solution

With nearly five decades of per- and polyfluoroalkyl substances (PFASs) being associated with firefighting and industrial activities, these compounds inevitably accumulate in both ground and surface water. PFAS contamination in water has emerged as a significant environmental and public health concern, particularly perfluorooctanesulfonic acid (PFOS), which is often found in higher concentrations compared to other PFAS and has more pronounced adverse health effects. Addressing PFAS contamination requires treating large volumes of water, making technologies that rapidly separate and concentrate PFASs highly favoured. The strong surface activity of PFAS, such as PFOS, enables them to generate colloidal gas aphrons (CGAs) during high shear mixing of their aqueous solutions, where PFASs can be separated and collected as foam. This study aims to evaluate the effectiveness of high shear mixing in separating PFOS from solution, leveraging its accumulation at air–water interfaces. High shear-assisted PFOS separation was tested by varying parameters like rotational speed (4000 to 10,000 rpm), mixing time (30 s to 30 min), and the effect of electrolytes. Results showed greater PFOS separation in the presence of electrolytes, particularly monovalent cations like Na+, compared to divalent cations such as Ca2+, due to the creation of more stable CGAs with smaller sizes. At a mixing rate of 6000 rpm, 85 % of PFOS was removed in 30 s from a highly contaminated PFOS solution (10 mg/L), with over 95 % separation after 5 mixing cycles. While high-shear mixing was efficient in PFOS separation from highly contaminated solutions it was less efficient for low-level contaminated solutions (less than 1 mg/L). These results suggest that hydrodynamic cavitation induced by high-shear mixing seems promising for enhancing the separation of PFOS from heavily contaminated solutions. This technique could serve as a standalone method or be integrated with other PFAS removal technologies to enhance the overall efficiency of PFAS removal from polluted water sources.

Production of resistant starch type 3 from cassava starch with high shear mixing and centrifugation treatment to increase its total dietary fibre content

SummaryCassava starch has a big potential to be a source material for producing low‐calorie starch by converting it to resistant starch. However, its original structure can prevent retrogradation of the amylose fraction to produce resistant starch so that reduce the total dietary fibre value. In this research, high shear mixing (HSM) is used to assist the gelatinisation process to provide disintegration of the cassava starch structure. Centrifugation was carried out to separate the top layers which have a high content of free amylose resulting in better retrogradation. The starch–water suspension was processed using HSM at a rotational speed of 9000–12 000 at 95 °C for 15 min. Then, the starch suspension was separated by centrifugation for 30 min. The product was then analysed using total dietary fibre (TDF), component carbohydrate analysis, scanning electron microscope (SEM) and x‐ray diffraction (XRD). From the analysis results, this method can increase the TDF content of the product up to 14.66% at 12 000 rpm.

Investigation on solid-liquid mass transfer and particle suspension of jet-flow high shear mixers

The jet-flow high shear mixer exhibits foreseeable advantages in intensifying diffusion-controlled solid-liquid reactions by its high-frequency mechanical impact. This study systematically investigated the influence of operational and structural parameters on solid-liquid mass transfer performance in JF-HSM. Combining experimental and simulation methods, suspension effect of solid particles in JF-HSM were assessed, and flow characteristics of particle two-phase flows were also analyzed. The results indicated that Njs was significantly influenced by rotor blade angle and stator bottom opening diameter, which increased by 1.77 and 1.47 times, respectively. The stator off-bottom clearance had a pronounced effect on kSLaSL, which increased by 90%. Furthermore, altering stator side opening ratio had minimal impact on both kSLaSL and Njs. Interestingly, acid concentration substantially affected kSLaSL, resulting in a maximum decrease of 24%, whereas Njs changed by only 3%. Correlations for kSL and Njs were established, providing theoretical guidance for applying and scaling JF-HSM in solid-liquid operations.

Improved high shear mixers enhance fast halogenation reactions of alcohols

In the view of green and sustainable synthesis, there is still a broad space for improvement with respect to the halogenations of the alcohol, which is facing up with the problems of high input and low yield. Herein, high shear mixers (HSM) were exploited first to enhance the bromination of tert-butyl alcohol by improving the mixing performance. Notably, the baffle plate (BP) was first proposed to facilitate the in situ separation of the product from the reaction system, promoting the reversible reaction equilibrium to shift toward the right direction. The influences of the molar ratio of reactants, temperature, feed rate, rotor speed, and height of BP were investigated on the reaction performance, which provides a facile and cost-efficient intensified technology to prepare 2-bromo-2-methylpropane. The maximum yield is achieved as 94.8% using HSM, obviously higher than that using CST (82.6%) and HST-Impeller (87.6%), and the reaction time can be shortened by 75%. Furthermore, such HSM and BP-HSM can successfully improve the yields of some fast alcohol halogenations with shorter reaction time. This ingenious exploration of BP in HSM provides valuable guidance on design new technology to intensify some fast organic chemical reactions with the products immiscible to the reactants.

Impact of Mixing Shear on Polymer Binder Molecular Weight and Battery Electrode Reproducibility

The viscosity and microstructure of Li-ion battery slurries and the performance of the resulting electrodes have been shown to depend on the mixing protocol. This work applies rheology to understand the impact of shear during mixing and polymer molecular weight on slurry microstructure and electrode performance. Mixing protocols of different shear intensity are applied to slurries of LiNi0.33Mn0.33Co0.33O2 (NMC), carbon black (CB), and polyvinyldiene difluoride (PVDF) in N-methyl-2-pyrrolidinone (NMP), using both high-molecular-weight (HMW) and low-molecular-weight (LMW) PVDF. Slurries of both polymers are observed to form colloidal gels under high-shear mixing, even though unfavorable interactions between high molecular weight PVDF and CB should prevent this microstructure from forming. Theoretical analysis and experimental results show that increasing shear rate during the polymer and particle mixing steps causes polymer scission to decrease the polymer molecular weight and allow colloidal gelation. In general, electrodes made from high molecular weight PVDF generally show increased rate capability. However, high shear rates lead to increased cell variability, possibly due to the heterogeneities introduced by polymer scission.

Enhancing the Techno-Functional Properties of Lentil Protein Isolate Dispersions Using In-Line High-Shear Rotor-Stator Mixing.

In response to global challenges such as climate change and food insecurity, plant proteins have gained interest. Among these, lentils have emerged as a promising source of proteins due to their good nutritional profile and sustainability considerations. However, their widespread use in food products has been impeded by limited solubility. This study aimed to investigate the potential of high-shear mixing, a resource-efficient technique, to enhance lentil protein solubility and its functional properties. Red lentil protein isolate powders were rehydrated and subjected to a semi-continuous in-line high-shear treatment at 10,200 rpm for a timespan ranging from 0 to 15 min. The results highlighted a significant (p < 0.05) increase in solubility from 46.87 to 68.42% after 15 min of shearing and a reduction in particle size as a result of the intense shearing and disruption provided by the rotor and forced passage through the perforations of the stator. The volume-weighted mean diameter decreased from 5.13 to 1.72 µm after 15 min of shearing, also highlighted by the confocal micrographs which confirmed the breakdown of larger particles into smaller and more uniform particles. Rheological analysis indicated consistent Newtonian behaviour across all dispersions, with apparent viscosities ranging from 1.69 to 1.78 mPa.s. Surface hydrophobicity increased significantly (p < 0.05), from 830 to 1245, indicating exposure of otherwise buried hydrophobic groups. Furthermore, colloidal stability of the dispersion was improved, with separation rates decreasing from 71.23 to 24.16%·h-1. The significant enhancements in solubility, particle size reduction, and colloidal stability, highlight the potential of in-line high-shear mixing in improving the functional properties of lentil protein isolates for formulating sustainable food products with enhanced techno-functional properties.

An experimental study of localized flow pattern, strain rate and turbulence kinetic energy dissipation rate of in-line teethed high shear mixer with different rotor and stator structures

The in-line teethed high shear mixers (HSMs) have been widely used in the chemical industry. However, there is still a lack of comprehensive understanding of the hydrodynamics characteristics about the attractive process equipment. In this paper, the effects of rotor and stator structures and rotor speed on flow characteristics of in-line teethed HSM are systematically studied by the particle image velocimetry experiment for the first time. The results show that increasing the rotor speed can significantly increase the strain rate (Sxy) and turbulence kinetic energy dissipation rate (ε). Especially, when the shear gap width is reduced from 1.5 mm to 0.5 mm, the mean ε increases by 96.8 %. Furthermore, two dimensionless correlations are established between the maximum value of the Sxy, ε and rotor and stator geometrical parameters to provide a valuable guidance for the geometrical design and optimization of in-line teethed HSM.

Evaluation of Stability and Enhancement of Nano Fluid Methods

Over the last ten years, there has been a substantial increase in research on nanofluids, and the findings indicate that these fluids are superior heat transfer fluids for application in engineering. The improved heat transfer is exclusively dependent on the thermal conductivity of the nanoparticles at constant particle volume concentrations and flow rates. By creating hybrid nanoparticles, one can change or vary the thermal conductivity of nanoparticles. Nanoscale particles with two or more separate components come together to form hybrid nanoparticles. Fluids made from hybrid nanoparticles are known as hybrid nanofluids. By utilizing more sophisticated materials, hybrid Nano fluids aim to significantly boost heat transmission. Results shows that the nanofluid stability is sensitive to environmental conditions including temperature, pH, and shear rate. It should be using surfactants, additives such as polymers and colloids, ultra-sonication, high shear mixing, applying magnetic field.

Optimization of the catalytic production of methyl stearate by applying response surface Box-Behnken design: an intensified green option for high-cetane biofuel manufacture.

To enhance the efficiency of processes by decreasing the reaction severity and energy consumption, and reducing the equipment size, facilities' space and operation cost, process intensification is an increasingly used option in the chemical industry. Within this framework and in agreement with some of the green chemistry principles (design for energy efficiency and use of renewable feedstocks), this work deals with the implementation of high-shear mixing (HSM) to intensify the homogeneous esterification of stearic acid (SA) with methanol to methyl stearate, a high-cetane number alkyl ester suitable to be added into biofuel streams. The response surface Box-Behnken design (BBD) is applied to quantify the main effects and two-way interactions of four key input reaction factors: methanol : SA ratio (7-16 mol mol-1), catalyst mass (0.25-4.0 wt%), temperature (40-60 °C), time (1-12 min), and to approximate the optimal conditions on the intensified SA esterification. The statistical BBD results indicates that the four linear effects, two of the four possible quadratic effects (catalyst mass and temperature) and only one (catalyst mass-time) of the six existing two-way interactions are statistically relevant at the 95% confidence level. Catalyst mass is the most influencing factor in the reaction, followed by methanol : SA ratio, temperature, and time. The proposed second-order regression model predicts that the intensified esterification requires only 12 min to practically convert all SA (99% ± 6.8%) running the reaction at 12.4 methanol : SA ratio, 4 wt% catalyst mass, 60 °C and 500 rpm, a value experimentally validated (93.2% ± 0.7%). Under these conditions and with the assistance of HSM, the typical reaction length of conventional heterogeneous and homogeneous-phase esterification processes decreases from 5 to 117 and 35 to 90 times, respectively.

Correlation between Optical Characteristics of Orodispersible Films with Selected Process Parameters Supported by FTIR Analysis

Paediatric and geriatric populations, as well as other special patient populations with swallowing problems, require patient-tailored dosage forms. One promising dosage form for these specific populations is orodispersible films.&lt;br /&gt; When preparing orodispersible films using sodium carboxymethyl cellulose as the film-forming polymer and glycerine as the plasticizer, it is essential to determine the optimal mixing time and mixing speed of the casting solution to achieve the desired transparency/opacity of the orodispersible films. In this paper, the primary focus is on mixing time and mixing speed, and determining how these two parameters can influence optical characteristics. All tested parameters are supported by FTIR analysis. The obtained results show that either a mixing speed of 7000 rpm on a high-shear mixer for 15 min or a mixing speed of 9000 rpm for 5 min can produce films with optimal optical characteristics.

Assessment of the impact of process and formulation variables on the prevalence of coating and coalescence mechanism in high shear mixer (Eirich mixer)

High shear mixing of powders in the presence of liquid addition can lead to the enlargement of primary powder particles, forming larger structures referred to as granules. This particle growth can occur through distinct mechanisms, including layering, coalescence, or a combination of both, and the prevailing mechanism is influenced by a multitude of process and formulation variables. In this study, we quantified the influence of process variables such as vessel inclination, rotational direction of the vessel, impeller speed, mixing duration, and rotation speed of the vessel pan on the particle growth mechanism. We accomplished this through rigorous image analysis of granule samples produced under varying conditions. Furthermore, our investigation extended to encompass the effects of formulation variables, including the particle density of the primary powder, the quantity of binder added, and the particle size of the coating material. Our findings revealed that the coating mechanism predominantly governed particle growth when the mixing time was brief, the mixer vessel had a high inclination angle, and the vessel rotated in a direction opposite to that of the agitator. The coating material utilization factor, denoting the ratio of the mass fraction of coating material added that effectively participates in the formation of coated seeds (each with a single seed) to the fraction of coating material engaged in competing mechanisms, serves as a crucial indicator of the prevailing mechanism within specific process and formulation conditions.

Effect of the drying type on the properties of granules and tablets produced by high shear wet granulation

Although high shear mixers can represent a single-pot process, separate drying equipment is commonly employed. Limited literature exists on the use of a heating jacket coupled with a vacuum pump typically used in a single-pot setup, so this study compares the drying effects of a single-pot setup (DSP) and ventilated oven (DVO) on the properties of granules and tablets. Granules containing three actives of varying water solubility were produced and characterised. The results showed that DSP reduced the drying time and produced smaller, irregular, and weaker granules with different compression mechanisms. The tablets were produced and characterised. All tablets passed the uniformity test. Compression differences had no impact on tablet properties for poorly water-soluble actives, but altered properties for highly soluble actives due to increased active migration and crystallization on the granule surface. In conclusion, while DSP offers advantages, careful consideration of the drying technique is essential during product development.

The effect of mixing on the dispersibility of adhesive mixtures for inhalation. Comparison of high shear and Turbula mixers

This study investigates the effect of different mixers and the applicability of the mixing energy (ME) concept to dry powder formulations for inhalation. With the aim to step-wise build and expand this concept, adhesive mixtures of 2 % budesonide and lactose carrier were investigated, both with 1 % magnesium stearate (MgSt) added in a ‘coating’ step, and without, the latter referred to as ‘naked’ formulations. For high shear mixed formulations, the fine particle fraction (FPF) was found to increase with increasing ME up to 60 % and thereafter decreased, using the Novolizer device. The data could be well fitted to the modeling equation, thus confirming the validity of the ME concept. The naked formulations displayed a linear decrease in FPF with increasing ME, again showing the validity of the ME concept.For Turbula mixed formulations, FPF increased with increased mixing time (and mixing energy) for all batches. The naked (binary) composition reached to higher FPF values than for high shear mixing and the formulation with MgSt reached to FPF values around 60 %, demonstrating that it is possible to achieve the same high drug dispersibility with the Turbula mixer as for high shear mixer.An equation for calculation of mixing energy in Turbula mixing was set up in an analogous way to the equation for high shear mixing, which enabled direct comparison between the two mixers.

Droplet Size Distribution in Emulsions.

The droplet size in emulsions is known to affect the rheological properties and plays a crucial role in many applications of emulsions. Despite its importance, the underlying mechanisms governing droplet size in emulsification remain poorly understood. We investigate the average drop size and size distribution upon emulsification with a high-shear mixer for model oil-in-water emulsions stabilized by a surfactant. The size distribution is found to be a log-normal distribution resulting from the repetitive random breakup of drops. High-shear emulsification, the usual way of making emulsions, is therefore found to be very different from turbulent emulsification given by the Kolmogorov-Hinze theory, for which power-law distributions of the drop size are expected. In agreement with this, the mean droplet size does not follow a scaling with the Reynolds number of the emulsification flow but rather a capillary number scaling based on the viscosity of the continuous phase.

Hybrid green composites of PLA incorporated with upcycled waste cellulose and vermiculite

The work aims to utilize a hybridization method where vermiculite and waste cellulose fibers are embedded inside bio-based PLA to manufacture green composites with superior characteristic properties such as improved thermal conductivity, enhanced processability, and increased mechanical strength in the resulting green composites. The potential of polymeric composites for emerging greener material development is very high. Originating from this point, this article reports the experimental findings on a hybrid composite reinforcement strategy where two types of renewable materials are employed as co-reinforcement agents in a biodegradable polylactic acid (PLA) matrix. Green composite sample manufacturing was performed via high shear mixing (5000 rpm). Composite samples containing waste cellulose fibers (WC), (average diameter: 15 µm) and vermiculite platelets (VC), (average size: 1.4milimeters) as inclusions and a low crystallinity thermoplastic PLA matrix are targeted. Two-phase composites having 10, 20,30 wt% WC, 30 wt% VC, and hybrid composites having 15VC-15WC wt. % and 7.5VC-22.5WC wt. % are manufactured. Composite samples are then tested for their thermal, rheological, and mechanical responses. Thermal analysis suggests that thermal conductivity is improved by 68 % for PLA30VC samples and in hybrid composites, thermal conductivity is regulated by WC, while crystallinity is regulated by VC. Rheological measurements suggest both filler materials contribute to the processability of PLA, and hybrid composites are more readily processable than neat PLA at 200 °C. While the tensile strength remains the same in all composites, a 137 % increase in E modulus and 127 % increase in flexural modulus is achieved with hybrid composites. The damage modes and contribution of both inclusion types to macro and micro fracture mechanisms are discussed in detail. Overall, results suggested that a stronger, easily processable, and thermally more conductive yet stable superior material alternative could only be achieved by the synergistic use of WC fibers and VC platelets.