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Purpose – The purpose of this research is to synthesize modified thermoplastic sago starch (TPS) through in-situ mechanism by reacting sago starch with diphenylmethanediisocyanate (MDI) and castor oil simultaneously, resulting in a more homogenous and finer-sized polyurethane prepolymer (PUP).

Design/Methodology/Approach – The methods used were Thermal Gravimetric Analysis (TGA) and Differential Scanning Calorimetry (DSC) for thermal characterization and stability of PUP, modified TPS non-extracted and extracted with toluene and water.

Findings – TGA test results presented shows that PUP begins to decompose thermally at a temperature of 300–500 °C. Weight loss occurs rapidly between these temperatures and is completely discharged at a temperature of 500°C, which is called weight loss transition.

Research Limitations/Implications – When extracted with toluene and a water solvent, the melting point and latent heat of fusion slightly decreased; however, it is still higher than the original value of sago. In terms of thermal stability, modified TPS decomposes and loses weight at 150–200 °C in small quantities, continues with weight loss rapidly, and is completely discharged at 500°C. The thermal stability is considered high; thus, modified TPS application can be varied.

Practical Implications – DSC analysis and TGA shows that modified TPS has good thermal characteristics and thermal stability. Modified TPS has a melting point of 104.69°C, and the latent heat of fusion (ΔH) is 234.27 J/g. This value is close to the PUP melting point and latent heat of fusion, which reveals the formation of cross-link between the starch and PUP.