BC sheets can be prepared in two forms: direct press-drying of the as-synthesised BC pellicle or disintegrating the BC pellicle to create a homogenous BC-in-water suspension prior to producing the BC sheet. We found that BC sheet prepared from direct press-drying of pristine pellicle was more homogeneous due to its better BC network formation and possessed higher specific surface area (46 g m−2), better resin impregnation and mechanical properties compared to its disintegrated pellicle counterpart (21 g m−2). BC-poly(acrylated epoxidised soybean oil) (polyAESO) nanocomposites consisting of BC sheet prepared from pristine pellicle was optically transparent whilst BC-polyAEO nanocomposites consisting of BC sheet prepared from disintegrated pellicle was opaque. Whilst the tensile properties of BC-polyAESO nanocomposites from pristine pellicle were higher, the fracture toughness of BC-polyAESO composite consisting of BC sheet from disintegrated pellicle was better. The lack of resin impregnation in BC-polyAESO from disintegrated pellicle led to a laminated structure, which utilised the fracture toughness of BC sheet effectively.