Natural fibre-reinforced composites (NFCs) have attracted attention as sustainable alternatives to synthetic fibre composites. However, their hydrophilic nature and susceptibility to moisture absorption, especially in combination with process-related defects, can compromise long-term performance. This study critically examines the effects of hydrophobic fumed silica, incorporated into an epoxy matrix, on the processing, moisture uptake, and mechanical properties of flax/epoxy laminates produced via resin transfer moulding (RTM). Epoxy systems containing 0–5 wt% silica were characterised in terms of particle dispersion, rheological properties, thermal behaviour, and water absorption. Corresponding laminates were analysed for void content, Fickian diffusion behaviour, and tensile performance in dry and saturated states. Despite its hydrophobic surface treatment, silica increased resin water uptake and, at 5 wt%, led to a substantial rise in viscosity, poor fibre impregnation, and increased porosity. The resulting laminates exhibited faster and higher moisture uptake and significantly reduced wet mechanical properties, especially for highly filled systems. While thermal stability improved slightly, the overall findings revealed that the chosen silica-based matrix modification led to clear trade-offs and processing limitations under RTM conditions. This study highlights the importance of assessing such limitations early in the design process and demonstrates that the selected silica type is not a viable strategy for improving moisture resistance in NFCs.

While size effects in composite structures have been widely studied under quasi-static uniaxial loading, their influence under fatigue conditions, particularly in the presence of multiaxial stress states and elevated temperatures, remains insufficiently understood. This study investigates the fatigue behaviour of thick-walled $\pm {45}^{\circ }$ braided glass fibre-reinforced polyurethane composite box structures under varying temperature and loading conditions. A combined experimental approach is adopted, coupling quasi-static and fatigue tests on large-scale structures with reference data from standardised coupon specimens. The influence of temperature (23–80 °C) and multiaxial shear–compression loading is systematically evaluated. The results demonstrate a significant temperature-dependent decrease in compressive strength and fatigue life, with a linear degradation trend that aligns closely between the box structure and coupon data. Under moderate multiaxial conditions, the fatigue life of box structures is not significantly impaired compared to uniaxial test coupon specimens. Complementary non-destructive testing using air-coupled ultrasound confirms these trends, demonstrating that guided-wave phase-velocity measurements capture the evolution of anisotropic damage and are therefore suitable for in situ structural health monitoring applications. Furthermore, these findings highlight that (i) the temperature-dependent fatigue behaviour of thick-walled composites can be predicted using small-scale coupon data and (ii) small shear components have a limited impact on fatigue life within the studied loading regime.