Towards Sustainable High-Performance Materials: Tailoring the Mechanical Properties of Bamboo-Based Fiber Composites through Controlled Processing

• Property tuning of BFCs was prepared using a controlled processing methodology. • Mechanical properties of BFCs rise with density and fall with resin content. • Enhanced property of BFCs was attributed to improved bonding and densification . Bamboo-based fiber composites (BFCs) have gained popularity in construction and outdoor applications. Nevertheless, enhancing their mechanical properties fulfill broader engineering demands remains a critical challenge. This study investigated the fabrication and property tuning of BFCs using a controlled processing strategy. Mechanical dissociation and delignification pretreatments were synergistically implemented to enhance resin impregnation and create a multi-scale reinforced bonding interface within the BFCs structure. The BFCs exhibited superior mechanical properties, with a flexural strength of 507 MPa, a tensile strength of 854.1 MPa, a compressive strength of 202.5 MPa, a flexural modulus of 35.9 GPa, and a tensile modulus of 60.8 GPa. Additionally, the BFCs demonstrated excellent impact resistance and thermal stability. Parametric studies revealed a strong positive correlation between mechanical properties and densification, whereas set resin content exhibited an inverse dependence. The optimal performance of BFCs was achieved at a density of 1.35 g cm −3 with a phenolic resin (PF) content of 10 %, significantly outperforming other common structural materials. Analysis of the material’s bending damage patterns revealed that compression densification and interfacial reinforcement were key contributors to the enhanced mechanical performance. This study provides a scientific foundation for advancing the development and application of high-performance BFCs, contributing to a more sustainable and low-carbon future.