Investigation into the material properties of wooden composite structures with in-situ fibre reinforcement using additive manufacturing

In contrast to subtractive manufacturing techniques, additive manufacturing processes are known for their high efficiency in regards to utilisation of feedstock. However the various polymer, metallic and composite feedstocks used within additive manufacturing are mainly derived from energy consuming, inefficient methods, often originating from non-sustainable sources. This work explores the mechanical properties of additively manufactured composite structures fabricated from recycled sustainable wood waste with the aim of enhancing mechanical properties through glass fibre reinforcement. In the first instance, samples were formed by pouring formulation of wood waste (wood flour) and thermosetting binder (urea formaldehyde), with and without glass fibres, into a mould. The same formulations were used to additively manufacture samples via a layered deposition technique. Samples manufactured using each technique were cured and subsequently tested for their mechanical properties. Additively manufactured samples had superior mechanical properties, with up to 73% increase in tensile strength compared to moulded composites due to a densification of feedstock/paste and fibre in-situ directional alignment