The present invention relates to a process for the manufacture of composite materials having lignocellulosic fibres dispersed in a
thermoplastic matrix, while generally maintaining an average fibre length not below 0.2 mm. The process comprises
defibrillation of the lignocellulosic fibres using a mixer and at a temperature less than the
decomposition temperature of the fibres in order to separate the fibres and generate microfibres, crofÊbres, followed by dispersion of the fibres in the
thermoplastic matrix by mechanical mixing to get the moldable
thermoplastic composition, followed by injection, compression,
extrusion or compression injection molding of said composition. The process produces high performance composite materials having a tensile strength not less than about 55 MPa, a
flexural strength not less than about 80 MPa, a stiffness not less than about 2 GPa, notched
impact strength not less than about 20 J / m, and un-notched
impact strength not less than about 100 J / m. The composite materials of the present invention are well-suited for use in automotive,
aerospace, electronic, furniture, sports articles, upholstery and other structural applications.