This study investigates the mechanical, structural, morphological, and thermal properties of chemically treated and untreated sugarcane bagasse fibers (SCB). Various concentrations of NaOH were used for the treatment over four hours. The main goal was to investigate the impact of alkali treatment on the overall properties of SCB fibers intended for composite applications. The results indicated that the crystallinity index, thermal stability, and mechanical properties were improved with the treatment, and this is due to the removal of impurities initially present on the outer surface of the SCB fiber and the reduction of amorphous components. This improvement may facilitate better adhesion between the SCB fibers and the polymeric matrices in biocomposite applications. However, it is important to determine the optimal concentration of NaOH that improves the properties of the SCB fiber without damaging the fiber’s structure.

This work focused on the development of eco-friendly bio-composites based on polylactic acid (PLA) and sugarcane bagasse (SCB) as a natural fiber from Moroccan vegetable waste. First, the fiber surface was treated with an alkaline solution to remove non-cellulosic components. Then, the composite materials with various amounts of treated sugarcane bagasse (TSCB) were fabricated using two routes, melt processing and solvent casting. The primary objective was to achieve high fiber dispersion/distribution and homogeneous bio-composites. The dispersion properties were analyzed using scanning electron microscopy (SEM). Subsequently, the thermal, mechanical, and melt shear rheological properties of the obtained PLA-based bio-composites were investigated. Through a comparative approach between the dispersion state of fillers with extrusion/injection molding and solvent casting method, the work aimed to identify the most suitable processing route for producing PLA-based composites with optimal dispersion, improved thermal stability, and mechanical reinforcement. The results support the potential of TSCB fibers as an effective bio-based additive for PLA filament production, paving the way for the development of eco-friendly and high-performance materials designed for 3D printing applications. Since the solvent-based route did not allow further improvement and presents clear limitations for large-scale or industrial implementation, the transition toward 3D printing became a natural progression in this work. Material extrusion offers several decisive advantages, notably the ability to preserve the original morphology of the fibers due to the moderate thermo-mechanical stresses involved, and the possibility of manufacturing complex geometries that cannot be obtained through conventional injection molding. Although some printing defects may occur during layer deposition, the mechanical properties obtained through 3D printing remain promising and demonstrate the relevance of this approach.

In this work, laminated polyester thermoset composites based on palm tree fibers extracted from palms leaflets and glass mats fibers were manufactured to develop hybrid compositions with good mechanical properties; the mixture of fibers was elaborated to not exceed 25 vol.%. Samples were prepared with a resin transfer molding (RTM) method and mechanically characterized using tensile and flexural, hardness, and impact tests, and ultrasonic waves as a non-destructive technique. The water sorption of these composite materials was carried out in addition to solar irradiation aging for approximately 300 days to predict the applicability and the long-term performance of the manufactured composites. Results have shown that the use of glass fibers significantly increased all properties; however, an optimum combination of the mixture could be interesting and could be developed with less glass sheet and more natural fibers, which is the goal of this study. On the other hand, exposure to natural sunlight deteriorated the mechanical resistance of the neat resin after only 60 days, while the composites kept high mechanical resistance for 365 days of exposure.

This study investigates the development of environmentally improved hybrid composites by incorporating sugarcane bagasse (SCB) fibers (15 wt.%) and hydrophobic nano‐clay fillers (3 wt.%) into a polypropylene (PP) matrix. Although PP is a petroleum‐based thermoplastic, its widespread availability, recyclability, and compatibility with conventional processing routes make it a suitable matrix for transitional sustainable composite systems. The sustainability of the proposed materials is primarily achieved through the valorization of agro‐industrial waste and the partial replacement of synthetic reinforcements without increasing polymer content. The composites were fabricated via twin‐screw extrusion, a scalable and energy‐efficient processing technique that enables uniform dispersion of multiscale reinforcements. Morphological, structural, and thermal characterizations were subsequently performed. Alkali treatment of SCB fibers was employed to improve fiber–matrix compatibility by removing surface impurities, increasing surface roughness, and enhancing interfacial stiffness. Furthermore, the use of a coupling agent (PP‐g‐MA) promoted strong interfacial adhesion between the bio‐based fibers, nano‐clay fillers, and the PP matrix, contributing to efficient stress transfer and reduced material failure. Thermal analysis revealed a slight increase in the crystallinity index for the hybrid sample, corresponding to an improvement of about 5%, attributed to the nucleating effect of fibers and nanoclays. In terms of mechanical performance, the Young's modulus of injection‐molded hybrid composites reached 2154 MPa compared to 1600 MPa for neat PP, representing an enhancement of nearly 35%. However, it was also observed that the Young's modulus increased from PP‐3D to PP‐M‐S‐3D, corresponding to an improvement of approximately 36%. A slight decrease was then recorded for the hybrid sample, attributed to defects between layers, as shown by the morphological analysis. Furthermore, the incorporation of organo‐modified nanoclays (OMMT) contributed to improved mechanical, thermal stability and structural integrity, suggesting a synergistic reinforcement effect. Overall, these results demonstrate the potential of multiscale PP‐based composites for developing more sustainable materials compatible with both conventional processing and additive manufacturing. The combined use of micro‐ and nano‐fillers improved thermal stability and adhesion. SEM and rheology confirmed good dispersion of fibers and nanoclays in the matrix. Tensile properties of injection‐molded and 3D‐printed samples were compared. Injection molding provided higher mechanical properties than 3D printing.

Eco-friendly biocomposites were prepared from poly(lactic acid) (PLA) plasticized with polyethylene glycol (PEG) and reinforced with Moroccan sugarcane bagasse fibers at 5, 10 and 15 wt%. The aim was to enhance PLA ductility through PEG incorporation while valorizing locally available lignocellulosic residues. Two processing methods, injection molding and melt extrusion additive manufacturing (MEX, 3D printing), were employed to investigate the influence of manufacturing method on the morphological, thermal, rheological and mechanical properties of the composites. Thermal analysis confirmed that PLA maintained its stability within the processing temperature range, supporting its suitability for MEX. Morphological observations revealed improved fiber dispersion and reduced porosity in injection-molded samples, whereas MEX-printed parts exhibited visible interlayer voids. These microstructural differences explained the superior tensile strength and modulus of injection-molded specimens compared to MEX ones.