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This study was aimed at considering the potential of wood-based composites processed using additive manufacturing as insulators in the building sector. A polylactic acid blend with 30% wood particles was used as a feedstock material in fused filament technology. Its thermal and mechanical properties were determined for various processing conditions, including printing temperature and infill rate. The results showed a minor contraction in its tensile performance as a result of the printing process. The printing temperature had a negligible effect on its stiffness and a limited influence on the other engineering constants, such as the tensile strength and ultimate stress. The thermal properties of printed structures have been found to significantly depend on the infill rate. Although the tested 3D printed wood-PLA material exhibited good thermal properties, which were tuneable using the printing conditions, its performance was still 38% to 57% lower compared to insulators such as the glass wool of the synthetic foams used in the building sector.

In this study, digital light processing (DLP) was used to achieve 3D-printed composite materials containing photosensitive resin blended with starch and hemp fibers. The synthesis of 3D-printed composites was performed without heating, according to various material combinations ranging from pure photosensitive resin to a mixture of three phases, including resin, starch, and hemp fibers, with the weight content for each reinforcing phase reaching up to a third of the formulation. The morphology, composition, and structure of the 3D-printed composites were assessed using infrared spectroscopy, laser granulometry, X-ray diffraction, and optical and scanning electron microscopy. In addition, thermal behavior and mechanical performance were studied using calorimetry, differential scanning calorimetry, and tensile testing combined with high-speed optical imaging. The results showed that the post-curing step is a leading factor for improving the mechanical performance of the 3D-printed composites. In addition, hemp fiber or starch did not alter the tensile strength. However, the largest reinforcing effect in terms of stiffness improvement was obtained with starch. Additionally, starchy composites demonstrated the strongest dependence of heat capacity on operating temperature.

Few studies have reported the performance of Polylactic acid (PLA) flax feedstock composite for additive manufacturing. In this work, we report a set of experiments conducted by fused filament technology on PLA and PLA-flax with the aim of drawing a clear picture of the potential of PLA-flax as a feedstock material. Nozzle and bed temperatures are both combined with the printing angle to investigate their influence on structural and mechanical properties. The study shows a low sensitivity of PLA-flax to process parameters compared to PLA. A varied balance between shearing and uniaxial deformation is found consistent with tensile results where filament crossing at -45/+45° provides the optimal load-bearing capabilities. However, Scanning Electron Microscopy (SEM) and high-speed camera recording shows a limiting reinforcing effect of flax fibre due to the presence of intra-filament porosity and a significant amount of fibre pull-out resulting from the tensile loading. These results suggest that the quality of the bond between PLA matrix and flax fibre, intra-filament porosity, and surface roughness should receive more attention as well as the need for more continuous fibre reinforcement in PLA filaments to optimise the performance of PLA-flax printed materials.