Eco‐Efficient <scp>HDPE</scp> Composites Reinforced With Ceramic Gypsum Waste: <scp>RSM</scp>‐Based Optimization and Mechanical Performance Assessment

ABSTRACT This study focuses on the fabrication and optimization of high‐density polyethylene (HDPE) composites reinforced with ceramic waste molds (CWM), aiming to reutilize industrial waste for the development of sustainable construction materials. The effects of three key processing parameters—mixing temperature, mixing speed, and CWM content—were investigated and optimized using response surface methodology (RSM) based on a Box–Behnken design. The optimal processing conditions were identified as a mixing temperature of 175°C, a mixing speed of 50 rpm, and a CWM content of 20 wt.%. Under these conditions, the composite exhibited a tensile strength of approximately 24.57 ± 0.12 MPa, an elongation at break of around 579.42 ± 0.97%, and a stable torque of 16.0 ± 0.10 Nm, with experimental deviations of less than 2.6% from the predicted model. The developed quadratic regression models showed high goodness of fit ( R 2 &gt; 0.99), confirming their strong predictive capability. These findings demonstrate that CWM can serve as a reliable inorganic filler for HDPE matrices, enhancing mechanical properties and thermal stability while maintaining excellent processability. The optimized composites show promising potential for applications in eco‐friendly construction materials, including paving tiles, insulation panels, and structural packaging. These results confirm the innovation of using CWM as an eco‐friendly filler and highlight its industrial feasibility, contributing to sustainable materials development aligned with circular economy principles.