The growing interest in sustainable additive manufacturing has driven research into customized biocomposite filaments reinforced with natural fibers. This study evaluates the influence of flax fiber content (5–15 wt%) on the thermal, rheological, morphological, and mechanical properties of fully bio-based polyamide PA10.10 filaments intended for fused deposition modeling (FDM). Filaments containing up to 15 wt% flax fibers were produced using both conventional single-screw extrusion and the METEOR^® elongational mixer to compare shear- and elongation-dominated dispersive mechanisms. Increasing flax loading enhanced stiffness (up to +84% tensile modulus at 15 wt%) but also significantly increased porosity, particularly in METEOR-processed materials, leading to reduced strength and intrinsic viscosity. Microscopy confirmed fiber shortening during compounding and revealed porosity arising from moisture release and insufficient fiber wetting. Rheological analysis showed the onset of a pseudo-percolated fiber network from 10 wt%, while excessive porosity at higher loadings impeded melt flow and printability. Based on the combined evaluation of the mechanical performance, dimensional stability, and processability, a 5 wt% flax formulation was identified as the optimal compromise for FDM. A functional automotive demonstrator (Fiat 500 dashboard fascia) was successfully printed using optimized FDM parameters (nozzle 240 °C, bed 75 °C, speed 20 mm s⁻¹, 0.6 mm nozzle, 0.20 mm layer height, and 100% infill). The part exhibited controlled shrinkage and limited warpage (maximum 1.8 mm across a 165 × 180 × 45 mm geometry with a 3 mm wall thickness). Dimensional accuracy remained within ±0.7 mm relative to the CAD geometry. These results confirm the suitability of PA10.10/flax biocomposites for sustainable, lightweight automotive components and provide key structure–processing–property relationships supporting the development of next-generation bio-based FDM feedstocks.

The present study introduces an innovative blown coextrusion die technology designed to address a critical gap in the production of multilayer films. Unlike conventional systems, this novel die allows for the creation of films with a high number of layers, ensuring layer integrity even in the micro-nano scale. A key advancement of this die is its ability to increase the number of layers without extending the residence time since it does not require an additional multiplier element. The risk of thermal degradation can, thus be, minimized. The die can easily be combined with existing cast coextrusion technologies, making it very versatile. Stability maps were developed to define processability and, in association with rheological analysis, optimal processing windows were determined. This study highlights the potential of enhancing material efficiency by increasing the number of layers while reducing the need for high percentages of EVOH. The produced multilayer films exhibited strong layer adhesion without the use of tie layers, thus improving recyclability and supporting sustainability goals.