Manufacturing of Sustainable Composite Materials: The Challenge of Flax Fiber and Polypropylene

The widespread use of synthetic composite materials has raised environmental concerns due to their non-biodegradability and energy-intensive production. This paper explores the potential of natural composites, specifically flax–polypropylene, as a sustainable alternative to traditional composites for semi-structural applications. In fact, the mechanical properties of flax–polypropylene composites are similar to synthetic ones (such as those made with E-glass fibers). However, processing challenges related to fiber–matrix interaction and material degradation necessitate suited process parameters for this sustainable type of material. For this reason, this review highlights the importance of optimizing existing manufacturing processes, such as hot press molding, to better accommodate the specific characteristics of polypropylene–flax composites. By refining the parameters and techniques involved in hot press molding, researchers should overcome current limitations and fully capitalize on its potential to produce composite materials of optimal quality. Therefore, a comprehensive literature assessment was conducted to analyze the properties and processing challenges of flax–polypropylene composites. Key process parameters affecting the material’s performance are identified and discussed. By optimizing process parameters for flax–polypropylene composites, it is possible to develop a sustainable and high-performance material with a reduced environmental footprint. Further research is needed to scale up production and explore different applications for this sustainable composite material.