In the context of sustainable development, considerable interest is being shown in the use of natural fibres like as reinforcement in polymer composites and in the development of resins from renewable resources. This paper focuses on eco-friendly and sustainable green composites manufacturing using resin transfer moulding (RTM) process. Flax fibre reinforced bioepoxy composites at different weight fractions (40 and 55 wt%) were prepared in order to study the effect of water absorption on their mechanical properties. Water absorption test was carried out by immersion specimens in water bath at room temperature for a time duration. The process of water absorption of these composites was found to approach Fickian diffusion behavior. Diffusion coefficients and maximum water uptake values were evaluated; the results showed that both increased with an increase in fibre content. Tensile and flexural properties of water immersed specimens were evaluated and compared to dry composite specimens. The results suggest that swelling of flax fibres due to water absorption can have positive effects on mechanical properties of the composite material. The results of this study showed that RTM process could be used to manufacture natural fibre reinforced composites with good mechanical properties even for potential applications in a humid environment.

Fused deposition modelling (FDM)-printed parts can be treated with various post-processes to improve their mechanical properties, dimensional accuracy and surface finish. Samples of polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) parts are treated with annealing to study a ceramic powder mould’s effectiveness in order to avoid dimensional part deformation. The variables chosen are annealing temperatures and the usage of a ceramic powder mould to avoid part deformations. A flexural strength test was carried out to evaluate the mould’s influence on the mechanical properties of the part. The effectiveness of the mould has been evaluated mainly attending to the length of the part, because this is the dimension most affected by deformation. A polynomial approximation to a deformation’s length and the effectiveness of the mould allows for their prediction. Results obtained show that effectiveness increases with the annealing temperature. Nevertheless, mould effectiveness decreases when parts are fabricated with PLA, because it is a semi-crystalline thermoplastic, and it suffers a lower shrinkage during thermal post-process than amorphous polymers such as ABS. Attending to the flexural strength test, mould has no significant influence on the mechanical properties of the treated parts in both materials studied.

Nowadays, there is a growing interest for the use and development of materials synthesized from renewable sources in the polymer composites manufacturing industry; this applies for both matrix and reinforcement components. In the present research, a novel basalt fibre reinforced (BFR) bioepoxy green composite is proposed as an environmentally friendly alternative to traditional petroleum-derived composites. In addition, this material system was combined with cork as core material for the fabrication of fibre composite sandwich structures. Mechanical properties of both skin and core materials were assessed through flexural and tensile tests. Finite element (FEM) simulations for the mechanical stress analysis of the sandwich material were carried out, and a maximum allowable shear stress for material failure under bending loads was established. Permeability measurements of the basalt fabrics were carried out in order to perform numerical simulations of liquid composite moulding (LCM) processes on the PAM-RTM software. The proposed green-composite sandwich material was used for the fabrication of a longboard as a case study for a sports equipment application. Numerical simulations of the mould filling stage allowed the determination of an optimal mould filling strategy. Finally, the load-bearing capacity of the board was studied by means of FEM simulations, and the presented design proved to be acceptable for service.