Fabrication of PLA bio-composite reinforced with jute fiber and ESP fillers and optimization of mechanical properties via fuzzy logic approach

Conventional synthetic materials based composite contributes greatly to waste accumulation and landfill increase as petroleum based material as petroleum-based resins accounts for ≈40% of the global polymer market. Jute fibers were selected for their low cost, moderate strength, and biodegradability, while ESP fillers were incorporated to enhance the mechanical properties of the composite. Two samples were fabricated: Type A (without ESP fillers) and Type B (with ESP fillers). Mechanical tests showed that Type B exhibited superior tensile and flexural strength, compared to Type A. In contrast, Type A outperformed Type B in impact strength. A fuzzy logic-based model was developed. The existing composites often shows subpar results which is the result of weak fiber matrix adhesion and filler dispersion issues. The results indicate that this PLA-jute-ESP composite can serve as a viable alternative to conventional NFCs, promoting environmental sustainability while reducing production costs., minimizing the trial-and-error approach often seen in the industry Additionally, the fuzzy logic model enhances the ability to predict composite behavior. The novelty of this study lies in the development of a fully biodegradable PLA-jute-ESP fabrication method, which is cost-effective and addresses both environmental concerns by reducing reliance on petroleum-based matrices and bridging performance gaps in natural fiber composites (NFCs). The integration of a fuzzy logic model further enhances this approach by providing a scalable framework for optimizing green composites, offering a sustainable alternative to traditional metal-based composites in global green composite fabrication. Enabling tailored material designs for automotive, packaging, and construction applications. Furthermore, this study supports global sustainability goals by contributing to advancing high performance, biodegradable composites that minimizes resource depletion and fossil fuel reliance. • Fully biodegradable PLA-jute-ESP bio-composite was successfully fabricated. • ESP fillers enhanced tensile (1082 N) and flexural strength (153.13 N). • Impact strength peaked at 14.64 J in composites without ESP fillers. • Fuzzy logic model accurately predicted properties, reducing trial-and-error. • Sustainable, cost-effective alternative to conventional NFCs was developed.