Additive Manufacturing (AM) enables the fabrication of complex structures through a layer-by-layer material deposition process. It offers advantages such as short design cycles, high material efficiency, and suitability for intricate geometries compared to traditional subtractive methods. Among AM techniques, Fused Filament Fabrication (FFF) is one of the most widely used technique due to its affordability, ease of operation, and ability to print a variety of materials. Bio-nano composites bring a sustainable approach to AM of engineered materials to enhanced mechanical properties compared to unfilled polymers. This study focuses on the fabrication and characterization of nano flax fibre reinforced Poly-Lactic Acid (PLA) for FFF. Nano flax fibre aqueous suspension was produced through ultra fine friction grinding. The size distribution of nano flax particles in the fibre suspension was analysis using an analytical centrifuge (Lumisizer). The nano flax fibre reinforcement was introduced at varying concentrations of 1wt%, 3wt%, and 5wt% into the PLA matrix. The reinforcement was done by producing the master batch of PLA and nano flax fibre by freeze drying process.  The mixture of nano flax fibre suspension along with PLA dissolve in Dioxane solvent was used for freeze drying. The composite filaments were produced via twin-screw extrusion and subsequently used for AM. The fabricated filaments undergo thermal analysis to assess thermal decomposition, glass transition temperature, melting temperature and crystallization. Furthermore, the mechanical characterization is conducted to evaluate the influence of nano flax fibre on the structural integrity of the additively manufactured components. Fractography studies were carried out to examine the failure mechanisms of the AM composites. The results provide insights into the feasibility of using nano flax fibre as a reinforcement for sustainable and high-performance bio-composites in AM applications.
Keywords: Additive Manufacturing, Fused Filament Fabrication, Bio-Composite, Nano Flax Fibre, Characterization