Novel 3D printing techniques to integrate woven glass fibers for the fabrication of PLA-based composites

The low mechanical strength of the 3D-printed polymer, namely polylactic acid (PLA), limits it for load-bearing applications. Reinforcement with continuous fiber improves the mechanical properties but introduces anisotropy. However, woven fiber as reinforcement offers more uniform in-plane strength because of the bi-directional interlaced structure of woven fiber. This study investigates the integration of woven glass fiber (WGF) into PLA using fused filament fabrication (FFF) through three distinct fabrication methods. In the first method (M1), the 3D printing process was paused to apply an adhesive (PLA + dichloromethane (DCM)) on the surface of the 3D printed PLA, and then WGF was placed. In the second method (M2), WGF was impregnated in the adhesive and placed above the printed PLA layer. In the third method (M3), specimens were fabricated following the steps of M1 with additional heating and compression. Among the three methods, the specimen fabricated through M2 showed the best tensile properties (tensile strength of 43.04 MPa and tensile modulus of 825.11 MPa), attributed to improved fiber–matrix interfacial bonding.