Degummed silk filament was pulverized with a home-made machine to obtain silk fibroin (SF) powder, and the structure, morphology, and particle size of the SF powder were investigated. The individual spherical particles and aggregates with different morphology of silk fibroin coexisted in water. A waterborne polyurethane (WPU) aqueous dispersion was blended with the SF powder to prepare novel blended materials with improved physical properties. The average particle size and zeta potential of the WPU/SF aqueous dispersions were characterized. The result showed that the WPU/SF dispersion with higher SF content exhibited a less negative zeta potential and a larger average particle size. Furthermore, the effect of SF content on the morphology, miscibility, and mechanical properties of the resulting blended films was studied by scanning electron microscopy, wide-angle X-ray diffraction, dynamic mechanical thermal analysis, and tensile testing. The films showed an improved Young's modulus and tensile strength from 0.3 to 33.8 MPa, and 0.6 to 5.2 MPa, respectively, with the increasing of SF up to a content of 26 wt %. The negative charges in the periphery and the small particle size made a good effort on dispersing SF powder into the WPU matrix as small aggregates, and the SF powder led to the efficient strengthening of WPU materials. (C) 2010 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 48: 940-950, 2010