Processing composites reinforced with wood fibers into an ultra‐strong structural materials.

High‐performance composites reinforced with natural fibers are next‐generation structural materials due to their recyclability and light weight. Manufacturing composites with high strength has been a challenge. Here, we describe the manufacture of novel composites reinforced with wood fibers using densification by hot‐pressing and fixing by curing reaction with phenolic resin. This composite with 1.4 g/cm3 had high mechanical properties, high water stability, and aging‐resistance, and exhibited a flexural strength and internal bonding strength of 102.4 and 7.5 MPa, respectively. The strength and modulus are 1.5–6.0 and 1.3–28.1 times higher than those of most of the wood fibers reinforced composites. After immersing in water for 24 h, the water absorption and thickness swelling are only 1.3% and 0.8%, respectively. Scanning electron microscope characterization indicates that the cell wall is totally collapsed and became complete densification. And the collapsed cells are fixed by phenolic resin. This production strategy for the composites was shown to be universally effective for various species of natural fibers. These novel wood fiber‐reinforced composites were suitable for commercial manufacture in the current production line, making them a low cost and high‐performance alternative to automotive and aerospace industries. [ABSTRACT FROM AUTHOR]