This work is a collaborative effort between academia and industry to promote the development of new sustainable and profitable materials for manufacturing products. Incorporating wood flour particles (WF) in polypropylene (PP) grants environmental advantages in developing products that use renewable resources to manufacture PP/WF composites using the melt intercalation process. However, the interaction between a hydrophilic strengthening phase (wood flour) with a nonpolar polymer matrix (PP) is poor, resulting in deficient mechanical performance. This investigation details the use of graft and masterbatch coupling agents to evaluate their effects on mechanical parameters. The low compatibility between the constituents favors increasing the composites’ thermal properties because the reinforcing phase acts as a nucleating agent. PP showed typical mechanical behavior, with a marked necking and a wide deformation capacity of approximately 180%. The mechanical behavior of the PP/WF composites revealed an elastic region followed by a termination after their yield point, shortening the stress–strain curves and reducing their ductility at strain values of approximately 2–4%. Graft coupling agents have better intermolecular performance with PP than masterbatch coupling agents. The modulus of elasticity of the composites increased to around 82% relative to PP. Processing methods influenced the thermal properties of the composites. The melt-blending process promoted molecular orientation, while injection molding erased the thermomechanical history of the extruded pellets. The melting temperature was similar in the composites, so there was no evidence of thermal degradation. The results showed that the coupling agents favor the crystallinity of the PP over tensile strength. SEM observations showed insufficient adhesion between the WF and PP, which promotes a reduction in stress transfer during tensile testing. The WF particles act as fillers that increase the stiffness and reduce the ductility of composites.

The manufacturing process of the aircraft cabin interior panels is expensive and time-consuming, and the resulting panel requires rework due to damages that occurred during their fabrication. The aircraft interior panels must meet structural requirements; hence sandwich composites of a honeycomb core covered with two layers of pre-impregnated fiberglass skin are used. Flat sandwich composites are transformed into panels with complex shapes or geometries using the compression molding process, leading to advanced manufacturing challenges. Some aircraft interior panels are required for non-structural applications; hence sandwich composites can be substituted by cheaper alternative materials and transformed using disruptive manufacturing techniques. This paper evaluates the feasibility of replacing the honeycomb and fiberglass skin layers core with rigid polyurethane foams and thermoplastic polymers. The results show that the structural composites have higher mechanical performances than the proposed sandwich composites, but they are compatible with non-structural applications. Sandwich composite fabrication using the vacuum forming process is feasible for developing non-structural panels. This manufacturing technique is fast, easy, economical, and ecological as it uses recyclable materials. The vacuum forming also covers the entire panel, thus eliminating tapestries, paints, or finishes to the aircraft interior panels. The conclusion of the article describes the focus of future research.

In this work, henequen and ixlte plant fibers were carbonized in a horizontal quartz tube furnace. Several carbonized and non-carbonized fiber fabric configurations were impregnated with a bio-based epoxy resin through the infuseon process. The infrared spectra revealed characteristic bands of styrene instead of organic compounds, representing that the carbonization procedure was adequate to carbonize the plant fibers. The porosity volume ratio for the non-carbonized henequen laminates showed the highest number of voids >1.9%, and the rest of the composites had a similar void density between 1.2–1.7%. The storage modulus of the non-carbonized and carbonized henequen laminates resulted in 2268.5 MPa and 2092.1 MPa, respectively. The storage modulus of the carbonized ixtle laminates was 1541.4 MPa, which is 37.8% higher than the non-carbonized ixtle laminates and 12% higher than henequen composites. The laminates were subject to thermal shock cycling, and tomography scans revealed no alterations on the porosity level or in the cracks after the cycling procedure. Thermal shock cycling promoted the post-curing effect by increasing the glass transition temperature. The viscoelastic results showed a variation in the storage modulus when the carbonized fiber fabrics were located between natural fiber fabrics, which was attributed to more excellent compaction during the infusion process. Variations in the viscoelastic behavior were observed between the different types of natural fibers, which influenced the mechanical properties.