Synergistic enhancement of jute fiber epoxy composites using hybrid nano-silica and graphene for structural and thermal stability

• Hybridization of nano-silica and graphene enhanced jute composite performance synergistically. • 5 wt. % nano-filler loading achieved 60.6 % tensile and 46.7 % flexural strength improvement. • Thermal degradation onset shifted from 290 °C to 355 °C due to nano-barrier effect. • Specific wear rate reduced by 70.6 % and hardness increased to 98.7 Shore D. • Water uptake dropped to 2.85 %, comparable to neat epoxy, enabling humid-environment use. This study investigates the development of hybrid jute/epoxy composites reinforced with nano-silica and graphene, aiming to improve the structural, thermal, and environmental performance of natural fiber–based materials. The primary objective was to examine how the synergistic effect of hybrid nanofillers enhances the multifunctional properties of jute fiber–reinforced epoxy laminates while maintaining processing compatibility through vacuum-assisted resin infusion. The results demonstrated significant improvements in mechanical properties. The tensile strength increased from 45.2 MPa (neat epoxy) to 93.8 MPa at 5 wt.% hybrid loading, corresponding to an enhancement of ∼107 %. Flexural strength showed a 46.7 % improvement, while impact strength rose by ∼38 % compared to unmodified laminates. Hardness increased by ∼24 %, and the specific wear rate decreased by nearly 70 %, confirming the dual contributions of silica (surface hardening and crack blocking) and graphene (load transfer and lubrication). Thermal stability was also enhanced, with the onset degradation temperature shifting from 290 °C to 355 °C, the peak from 365 °C to 425 °C, and the char yield rising from 5.2 % to 21.4 %. Water absorption decreased by >50 %, attributed to interfacial sealing and tortuous diffusion pathways provided by the nanofillers. These findings highlight the potential of hybrid nano-silica/graphene reinforcements to deliver multifunctional improvements in natural fiber composites. The study establishes a pathway for developing sustainable, lightweight, and durable composites for structural applications in the automotive, marine, and building industries, where performance, cost efficiency, and environmental compatibility are equally critical.