In Situ Extrusion Processing of Treated and Untreated Pineapple Leaf Fibre-Reinforced PLA Composites for Improved Impact Performance

Material extrusion (MEX) 3D-printed parts are primarily used for prototyping rather than functional components due to lower mechanical strength. To address this limitation and promote sustainability, current work explores the reinforcement of plant-based polylactic acid (PLA) with pineapple leaf fibre (PALF). An in situ approach was proposed to embed continuous PALF within the middle layer of a 3D-printed component during the MEX process. An experimental investigation was conducted to evaluate the impact performance of composites produced via this new fabrication method. To optimize the fibre–matrix interface, an alkaline treatment was applied to the natural fibre, enhancing interfacial adhesion. Neat PLA, along with two types of PALF-reinforced PLA composite, were printed with both single-strand and three-strand fibre configurations. Fracture surfaces were analyzed under a digital microscope and a scanning electron microscope (SEM) to correlate morphological characteristics with the impact strength. The results showed that the impact strength of the three-strand treated PALF-PLA composite (3 PALF-PLA) surpassed that of neat PLA by 2.71% due to reduced porosity. In contrast, the one-strand PALF-PLA composites exhibited lower performance compared to neat PLA due to the presence of the fibre gap caused by the mid-print pause. Treated fibres consistently outperformed untreated ones due to their rougher surface morphology resulting from alkaline treatment. The results demonstrate that the combination of alkaline treatment and continuous fibre reinforcement significantly enhances energy absorption of 3D-printed MEX parts and offers a sustainable pathway for 3D-printed MEX parts.