Interest in natural fiber-reinforced polymer (NFRP) composites is growing rapidly in the transportation sector, especially as a replacement material for metals and synthetic fiber composites. The heightened interest is directly related to a need to produce lightweight and fuel efficient vehicles. Further, stringent legislation and greater environmental awareness is forcing transportation industries to select materials with a smaller carbon footprint. In such a context, NFRP composite materials are a good choice due to their low cost, low environmental impact, and relatively equivalent properties to metals and other composites. Most prior studies have examined commodity plastics such as polypropylene, polyethylene, and epoxy as the primary polymer matrix in NFRP composites and little work has addressed engineering plastics. Engineering plastics, which includes polycarbonate, polyamides, and polystyrene, are high performance thermoplastics with superior properties but relatively higher cost than commodity plastics. It has been claimed that even after recycling, engineering plastics properties are superior to those of commodity plastics, and thus, utilization of recycled engineering plastic in NFRP composites can help reduce waste and lower composite material costs. The aim of this review article is to explore the current status of engineering plastics reinforced with natural fibers such as flax, hemp, jute, and sisal and to examine their use in automotive, aerospace, and maritime applications. Properties and processing techniques of engineering plastics reinforced with natural fibers are also studied.

The aim of this study was to design a tooling system for manufacturing automotive components using a natural fiber polymer composite (NFPC) material. As a case study, an automotive battery cover was selected and a compression molding tool was designed, keeping in mind the need for the simplicity of the tool and ensuring the low cost of this process. However, since the original part was injection-molded with virgin polypropene, some vital changes made in the part and tool design process were documented as a guideline to show new designers how to approach the design of parts and tools using a natural fiber polymer composite material. Additionally, the challenges faced during the manufacturing of composite parts with the new tool were also documented and solutions to these challenges were suggested for large-scale production. Finally, compressive testing was performed to evaluate the performance of the structure of the designed part and to compare the recycled polymer with NFPC material. Both wood and palm fiber composite material perform better in compression testing compared to the recycled polymer material.

The aim of the present study was to investigate the effects of fiber content and then silane treatment on the mechanical performance of the natural fiber composites of recycled acrylonitrile–butadiene–styrene (ABS) provided by the automotive sector. Wood and palmyra fibers were used as fillers in 10% and 20% fiber content composites. The fibers were treated with N-(2-Aminoethyl)-3-aminopropyltrimethoxysilane to improve the interfacial adhesion between fibers and polymer matrices. The mechanical properties of the composites were determined by tensile and impact tests. Morphological analysis was later performed using a scanning electron microscope (SEM). According to the experiment results, the tensile and impact strength of both wood and palmyra fibers increase after silane treatment. However, for the low-wood-fiber-content composite, the tensile and impact strength decrease after silane treatment due to the presence of an excess amount of silane relative to fiber content. The addition of wood and palmyra fibers significantly improved the tensile modulus of composite material and further increases slightly after silane treatment. Finally, SEM analysis shows a homogenous mix of fibers and polymer matrices with fewer voids after silane treatment, thereby improving interfacial adhesion.

This paper presents the application of Taguchi design of experiment and Autodesk Moldflow® simulation in finding the optimal processing parameters for the manufacturing of natural fiber–polymer composite products. The material used in the study is a composite of recycled thermoplastic reinforced with 10% wood fibers. For the study, four critical processing parameters, namely compression time, mold temperature, melt temperate, and pressure, were selected for optimization. Process analysis was carried out in Moldflow® utilizing a combination of process parameters based on an L9 orthogonal array. Later, the warpage output from Moldflow® simulation was converted into a signal-to-noise (S/N) ratio response, and the optimum values of each processing parameter were obtained using the smaller-the-better quality characteristic. The results show that the optimum values were 60 °C, 40 s, 210 °C, and 600 kN for the mold temperature, compression time, melt temperature, and pressure, respectively. Afterward, a confirmation test was performed to test the optimum parameters. Using analysis of variance (ANOVA), melt temperature was found to be the most significant processing parameter, followed by mold temperature, compression time, and pressure.

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