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.

This study evaluates the thermal stability of polypropylene reinforced with argan nut shell particles. Improving thermal stability is crucial for enhancing material performance and durability. A full factorial design of experiments (DOE) was used to systematically evaluate the effects of extrusion parameters (temperature, speed) and material composition (filler content, coupling agent) on thermal stability. The DOE method proved effective in identifying the optimal conditions and revealed that the inclusion of a maleic anhydride coupling agent significantly improved the thermal degradation behavior, while high extrusion temperatures negatively affected it. The final elaborated composite using the optimal parameters showed enhanced thermal stability. These findings demonstrate the method usefulness in optimizing natural fiber-reinforced composites for better thermal performance.

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.