This research, structured in a six-phase iterative framework, decodes the rationale behind complex façade geometries & their dependence on conventional materials. Parallel with rising climate consciousness, the built environment is searching for mechanically competent, lower-impact material alternatives in the façade sector compatible with existing production infrastructure.
Literature finds potential within emergent natural fibre-reinforced polymers that fit the bill. As the pairing of Flax fibres and PLA constituents emerges as the best scientific fit, commercial façade products with natural fibre-reinforced polymers do not exist yet.

The review identified a significant research gap in fibrous biocomposites; despite existing research on the economic composite sheet-forming techniques, complex structures using developable surfaces on fibrous composite materials are yet to be reported. This study rethinks conventional cladding systems, connects the research gap to the built environment's quest, and questions biocomposites' viability as sheet materials for façade applications.
The methodology involved empirical inquiries at every level in developing a fibre-reinforced biocomposite with the geometric capabilities required of conventional façade material standards. The system design led to a 100% biobased laminate material – a Flax-PLA biocomposite – capable of adapting to developable surface geometries.

A systematic approach was developed using sheet-forming concepts to evaluate the ability of the biocomposite to be reshaped without compromising its structural integrity. Positioning the research with circular R-strategies, this study documents the pioneering attempt for continuous natural-fibre composites, demonstrating developability as an intrinsic material property never proved.
Key findings upon an extensive testing program reveal that the biocomposite retains its original strength and durability even after reshaping, demonstrating its potential for a circular loop. A lifecycle impact assessment and comparative analysis benchmarked the material with virgin aluminium sheet metal, showing promising carbon equivalent savings using the Flax-PLA panels. The biobased panels present significantly lower overall implications, even considering their current shorter service life, which can extend soon.

The findings demonstrate the feasibility of Flax-PLA composites as a circular and biobased alternative to conventional cladding materials. Forming and reshaping these panels into flat sheets without distortion allows for reusability and repurposing, retaining their embodied energy across multiple life stages. This paper proved developability with a scalable strategy as a catalyst for future research on biobased materials and to strengthen their presence in the built environment.