Spun cellulose filaments and biobased resins show strong potential as future sustainable materials in structural engineering, automobile manufacturing and aerospace technology. These materials display complementary properties appropriate for combination in bio-composite materials where cellulose forms the reinforcing component and the resin acts as a tough matrix. A major challenge concerns balancing structure and functional properties in the assembly process. In this work, we demonstrate that lightweight and superstrong bio-composites can be fabricated from biobased epoxies and aligned cellulose filaments via sequential stretching, vacuum infusion and densification process. Further, simulations based on shear stress analysis reveal that the proposed cellulose-dominant interface (60wt%) offers mechanical insights into the design and assembly of spun cellulose composites towards advanced macroscopic bioinspired structural materials. This research paves the way for the development of sustainable, high-performance bio-composites that could substitute conventional synthetic materials utilized in a variety of industries, reducing environmental impact without compromising on strength or functionality.

Keywords: Cellulose filaments, lightweight, bio-composite, mechanical properties.