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<p>Traditional 3D-printed composites often rely on short or randomly oriented natural fibers, which limit the full exploitation of their reinforcing potential. In this context, the present study introduces a novel approach by strategically incorporating continuous Agave sisalana fibers as an interleaved core within 3D-printed polylactic acid (PLA) biocomposites. This architecture aims to overcome existing limitations by enhancing fiber alignment, interfacial bonding, and mechanical performance, while maintaining the lightweight benefits of PLA. NaOH treatment improved fiber–matrix adhesion, as confirmed by Scanning Electron Microscopy (SEM). Mechanical testing revealed significant improvements in the treated fiber-interleaved composites compared to its neat counterpart: tensile strength increased by 36.19% and interlaminar shear strength by 46.25%. The treated fiber interleaved composite achieved a tensile strength of 40.87&#xa0;MPa and a tensile modulus of 2420.88&#xa0;MPa. Although the neat PLA exhibited the highest flexural strength (61.73&#xa0;MPa) and modulus (2560.11&#xa0;MPa), the treated fiber interleaved composites demonstrated superior toughness (938.9&#xa0;kJ/m³) and resilience (307&#xa0;kJ/m³) under tensile loading. Dynamic Mechanical Analysis (DMA) showed a lower damping factor (Tan δ = 0.53) for treated fiber interleaved composites, indicating reduced molecular mobility and improved thermal stability, compared to neat PLA (Tan δ = 1.49; storage modulus = 1130&#xa0;MPa). Additionally, impact testing highlighted the superior energy absorption capability of untreated fiber interleaved composites, with the highest puncture force (349.78&#xa0;N), greater deformation (12.50&#xa0;mm), and lower impactor end velocity (1.43&#xa0;m/s). These findings validate the effectiveness of strategically interleaved continuous fiber architecture in enhancing the multifunctional performance of 3D-printed PLA composites. Additionally, future studies can explore the effects of altering the stacking sequence and adjusting the fiber volume fraction to further optimize composite performance.</p>

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Performance of strategically interleaved continuous sisal fiber core 3D printed PLA composites for engineering applications

  • 期刊论文

  • 发表日期：

    2026年2月18日

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  • Mohit Kumar,
  • Vinod Ayyappan,
  • Ranvijay Kumar,
  • Manoj Kumar Singh,
  • Sanjay Mavinkere Rangappa,
  • Suchart Siengchin

摘要

Traditional 3D-printed composites often rely on short or randomly oriented natural fibers, which limit the full exploitation of their reinforcing potential. In this context, the present study introduces a novel approach by strategically incorporating continuous Agave sisalana fibers as an interleaved core within 3D-printed polylactic acid (PLA) biocomposites. This architecture aims to overcome existing limitations by enhancing fiber alignment, interfacial bonding, and mechanical performance, while maintaining the lightweight benefits of PLA. NaOH treatment improved fiber–matrix adhesion, as confirmed by Scanning Electron Microscopy (SEM). Mechanical testing revealed significant improvements in the treated fiber-interleaved composites compared to its neat counterpart: tensile strength increased by 36.19% and interlaminar shear strength by 46.25%. The treated fiber interleaved composite achieved a tensile strength of 40.87 MPa and a tensile modulus of 2420.88 MPa. Although the neat PLA exhibited the highest flexural strength (61.73 MPa) and modulus (2560.11 MPa), the treated fiber interleaved composites demonstrated superior toughness (938.9 kJ/m³) and resilience (307 kJ/m³) under tensile loading. Dynamic Mechanical Analysis (DMA) showed a lower damping factor (Tan δ = 0.53) for treated fiber interleaved composites, indicating reduced molecular mobility and improved thermal stability, compared to neat PLA (Tan δ = 1.49; storage modulus = 1130 MPa). Additionally, impact testing highlighted the superior energy absorption capability of untreated fiber interleaved composites, with the highest puncture force (349.78 N), greater deformation (12.50 mm), and lower impactor end velocity (1.43 m/s). These findings validate the effectiveness of strategically interleaved continuous fiber architecture in enhancing the multifunctional performance of 3D-printed PLA composites. Additionally, future studies can explore the effects of altering the stacking sequence and adjusting the fiber volume fraction to further optimize composite performance.