Production and Characterization of Lightweight and High‐Strength Natural/Synthetic Fiber Hybrid Composites for High‐Impact Applications

ABSTRACT This study presents the development of a thermoplastic‐based high‐impact nano‐hybrid composite, formulated by incorporating 2 wt% jute nanofibers into a matrix of polystyrene, natural rubber, and waste polypropylene (PS/NR/wPP), reinforced with both synthetic (Kevlar) and natural (jute) fibers via compression molding. The composites were evaluated for their mechanical, thermal, physical, and morphological properties. Among the formulations, the hybrid composite comprising four layers of Kevlar and two layers of jute (4K2J) exhibited the highest impact resistance as well as superior tensile strength and elastic modulus. However, no significant improvement was observed in elongation at break. Dynamic mechanical analysis (DMA) indicated an approximately 16% enhancement in the damping factor, reflecting improved energy absorption, while the storage and loss moduli showed marginal increases. Scanning electron microscopy (SEM) revealed features such as jute fiber fracture, splitting, void formation, and matrix delamination. Kevlar and hybrid composites demonstrated microstructural responses to impact, including delamination, micro‐buckling, splitting, fracture, and fibrillation. Overall, the results confirm that the developed composite exhibits excellent mechanical performance and high energy absorption, making it a promising candidate for high‐impact applications.