Layer-Paused FFF-Based Manufacturing of PLA-Hemp Composites: Mechanical Behavior and Failure Morphology

Abstract

In this study, polylactic acid (PLA)-hemp composite samples were fabricated using a layer-paused fused filament fabrication (FFF) method, in which natural hemp fibers were manually inserted into pre-designed internal channels generated via computer-aided design (CAD). The novelty of this work lies in the introduction of a simple yet effective manufacturing approach that enables the direct integration of continuous natural fibers into the FFF process without requiring filament modification. This approach allows controlled fiber alignment and improved structural performance while maintaining the accessibility and sustainability of the FFF technique. Mechanical testing revealed that hemp fiber reinforcement increased the maximum tensile force from 1545 N to 1999 N (30%), while the displacement at maximum force decreased from 7.8 mm to 7.2 mm (8.7%), indicating a moderate reduction in ductility. Scanning electron microscopy (SEM) further confirmed the presence of fiber pull-out and interfacial separation as dominant fracture mechanisms. These results highlight the potential of the proposed method for advancing sustainable natural fiber-reinforced composites produced via additive manufacturing.

Affiliated Institutions

• Karabük University TR

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