Unravelling the Potential of Jute Fibre-Based Green Filament Composites via Fused Deposition Modelling

This chapter presents a comprehensive investigation into the development, processing, characterization, and future scope of jute fibre-reinforced polylactic acid (PLA) green filament composites fabricated through fused deposition modelling (FDM). As industries move towards sustainable alternatives in manufacturing, the use of biodegradable and bio-based materials such as jute offers an eco-friendly solution for reducing reliance on petroleum-derived composites. This chapter begins by detailing the surface treatment and micronization of jute fibres, followed by the fabrication of composite filaments using a custom-designed, low-cost extrusion system. These filaments are then used to 3D print ASTM-standard tensile specimens, whose mechanical properties and emission profiles are evaluated. The influence of key FDM parameters—nozzle temperature, bed temperature, and infill density—on tensile strength and ultrafine particle emissions is systematically analysed using statistical tools. Parametric analysis, regression modelling, and multi-objective optimization techniques like VIKOR (VlseKriterijumska Optimizacija I Kompromisno Resenje) and Particle Swarm Optimization are employed to identify optimal process configurations. The findings demonstrate that jute/PLA composites can achieve tensile strengths up to 47.5 MPa, while also emitting significantly fewer airborne pollutants than traditional FDM materials. This chapter concludes by outlining future research directions, including advanced fibre modifications, life cycle assessments, artificial intelligence-assisted manufacturing, and application-specific functionalization.