Sustainable Synthesis and Characterization of Wood-Fiber Reinforced PLA for Additive Manufacturing Applications

The rising demand for environmentally responsible manufacturing has intensified interest in biodegradable polymers for additive manufacturing (AM). Polylactic Acid (PLA), a bio-based thermoplastic, is widely utilized due to its renewability and ease of processing. However, its inherent brittleness, low thermal resistance, and limited mechanical strength restrict its suitability for structural or load-bearing applications. This study addresses these limitations by developing and characterizing wood fiber (WF)-reinforced PLA composites aimed at improving mechanical performance and sustainability in AM, particularly Fused Deposition Modeling (FDM). Although natural fiber-reinforced biopolymers have shown promise, prior research often neglects eco-friendly processing, cost-effective preparation, and systematic optimization of fiber content and printing conditions. To overcome these gaps, sustainable composite filaments were produced using solvent-free melt compounding and extrusion techniques. Standardized specimens were fabricated via FDM and subjected to tensile, flexural, and compressive testing to assess mechanical properties. A multi-criteria decision-making (MCDM) approach was further employed to optimize printing parameters, balancing strength, energy efficiency, and material utilization. Results demonstrate that PLA-WF composites exhibit significant property enhancements, with tensile and flexural strengths improving by ~18% and ~22%, respectively, compared to neat PLA. The addition of WF not only strengthens structural performance but also lowers cost and reduces environmental impact, while maintaining good printability and dimensional stability. These findings highlight the potential of PLA-WF composites as sustainable alternatives for functional AM components and align with multiple United Nations Sustainable Development Goals (SDGs), including SDG 9, SDG 12, SDG 13, and SDG 15.