AbstractContinuous plant yarn‐reinforced polylactic acid (PLA) composites were produced through in situ 3D printing, focusing on how plant fiber attributes influence the crystallization, mechanical, and rheological properties of the printed composites. The aim of this study was to assess the viability of plant fibers as substitutes for synthetic ones in engineering additive manufacturing. Plant fibers promoted the crystallization of PLA due to their shear induction and nucleation agent induction effects. The inherent triangular void defect during printing decreased with increasing plant fiber‐volume fraction. Rheological analysis revealed a transition to more elastic behavior post‐fiber addition, indicating solid‐like properties. The tensile strength of flax fiber‐yarn/PLA composite (volume fraction of 50.79%) was 342.37% higher than that of pure PLA, with a 22.2% lower density than pure PLA. Flax fiber demonstrated a superior reinforcement effect than carbon fiber in compressive strength for 3D printed honeycomb sheets with lower energy consumption and footprint. Optimizing fiber characteristics holds promise for high‐performance 3D‐printed natural fiber composites, particularly in vehicle applications.Highlights Plant fiber/polylactic acid (PLA) composites were in situ printed with a volume fraction of 50.79%. Plant fibers promoted the crystallization of PLA during the printing process. The tensile strength of flax fiber/PLA increased by 342.3% with a 22.2% lower density than PLA. Flax fiber showed a better reinforcement than carbon fiber in a compressive test of printed honeycomb.
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