Abstract

This study develops a sustainable composite material for UAV blades using woven polylactic acid (PLA) and date palm fiber (DPF). The biodegradable PLA matrix reinforced with DPF provides a lightweight and high-strength alternative to conventional epoxy–glass fiber or carbon fiber composites, while significantly reducing environmental impact. DPF was first extracted and chemically treated to enhance surface adhesion. The fibers, with an average diameter of 220 μm, were spun into yarns and woven into plain-weave fabrics with controlled uniformity. The woven mats were impregnated with PLA, ensuring effective fiber coating, improved moisture resistance, and the formation of prepreg textile sheets and molded to fabricate the UAV blade. The resulting composite exhibited a laminate thickness of 3 mm, suitable for aerodynamic blade design. Mechanical characterization showed tensile strength of 95 MPa and flexural strength of 150 MPa, with a specific modulus competitive with glass fiber composites at a fraction of the weight. Optimized fiber extraction and weaving improved fiber–matrix bonding, while the plain weave configuration ensured stable load distribution under bending stresses.

The proposed PLA/DPF composite demonstrates strong potential for UAV applications by combining structural integrity, weight reduction, and biodegradability. It not only upcycles agricultural waste but also offers a sustainable alternative to petroleum-based composites, enabling lower carbon footprint and end-of-life recyclability.

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Mr. Ahmed Alshehri