Influence of temperature and layer height on the structural and mechanical properties of continuous biocomposites by in–nozzle impregnation additive manufacturing

Abstract

Purpose

This study aims to assess the relationships between limit parametric settings of in-nozzle impregnation additive manufacturing, namely, nozzle temperature and layer height, on the micromorphology and induced mechanical properties of continuous flax yarns-reinforced biocomposites.

Design/methodology/approach

The additively manufactured biocomposites with different printing parameters were characterized by X-ray microcomputed tomography and tensile testing to link the process–structure–properties relationships regarding the internal morphologies of yarns, matrix and porosities and tensile properties.

Findings

Several types of morphology were defined regarding fiber, void, raster and interfaces. The results showed a competition between porosity development, coating effect and variation in fiber volume fraction on the biocomposite quality and mechanical performance when simultaneously varying the layer height and the temperature due to rheology-related phenomena and process-induced defects.

Originality/value

To the best of the authors’ knowledge, no previous study has been carried out on the relation between the internal micromorphologies in three directions of continuous biocomposites manufactured by in-nozzle impregnation additive manufacturing and the limit printing parameters. The findings are thought to help manufacturers master this technology for high-end applications.

Citation

Wu, X., Ginoux, G., Paux, J. and Allaoui, S. (2025), "Influence of temperature and layer height on the structural and mechanical properties of continuous biocomposites by in–nozzle impregnation additive manufacturing", Rapid Prototyping Journal, Vol. ahead-of-print No. ahead-of-print. https://doi.org/10.1108/RPJ-06-2024-0255