Research on the Preparation of Polylactic Acid/Bamboo Fiber Composite Materials and Their 3D Printing Process

The increasing need for lightweight, personalized, and sustainable orthopedic braces has motivated the development of bamboo fiber (BF)-reinforced polylactic acid (PLA) composites. In this study, BF/PLA composites were prepared by melt blending. The effects of polybutylene adipate terephthalate (PBAT) toughener, BF content, and a silane coupling agent on the mechanical properties were evaluated, along with their suitability for 3D printing foot braces. The results showed that at a PLA/PBAT mass ratio of 85/15 and a bamboo fiber content of 10 wt.%, the impact strength of the composite reached 7.7 kJ/m². Silane treatment of BF further improved the impact strength, with a maximum value of 11.3 kJ/m² achieved at a silane/BF mass ratio of 2/98. The optimized composite exhibited good printability across nozzle temperatures of 190-210 °C. Printing speed significantly influenced the process; a speed of 35 mm/s enabled successful fabrication of the foot brace, whereas higher or lower speeds led to model collapse due to overheating or cracking caused by insufficient interlayer adhesion. This study successfully developed a bamboo fiber-reinforced PLA composite suitable for 3D printing of orthopedic braces and identified the optimal 3D printing process parameters.