Starch acetate-corn fiber foams were prepared by extrusion. Corn starch was acetylated (DS 2) to introduce thermoplastic properties. Corn stalks were treated with sodium hydroxide to remove the lignin and to obtain purified cellulose fibers. Starch acetate was blended with treated fiber at concentrations of 0, 2, 6, 10, and 14% (w/w) and extruded in a corotating twin-screw extruder with 12 to 18% w/w ethanol content and 5% talc as a nucleating agent. The samples were extruded at 150degreesC and selected physical and mechanical properties were evaluated. Micrographic properties were analyzed using scanning electron microscopy to observe the interaction of fiber and starch. Fiber incorporation at the lower concentrations enhanced the physical properties of the foams. Fiber contents greater than 10% decreased expansion and increased density and shear strength. Good compatibility between starch and corn fiber was observed. (C) 2004 Wiley Periodicals, Inc.