Mechanical performance of natural fiber reinforced polymer composites with critical assessment of recent advances and future perspectives

Abstract The accelerating industrial demand for sustainable materials has precipitated a fundamental paradigm shift from synthetic to naturally derived fibers in composite manufacturing. Natural fiber-reinforced composites (NFRCs) have emerged as the preferred reinforcement over petrochemical-based alternatives, attributable to their superior economic viability, health advantages, and environmental sustainability credentials. These composites demonstrate commendable mechanical properties while offering inherent advantages, including natural abundance, reduced weight, biodegradability, and enhanced dielectric characteristics. Enhanced flexibility in composite manufacturing can be achieved through hybrid architectures, wherein multiple natural fiber types are strategically incorporated. This comprehensive review distinctively presents a critical examination of natural fiber-reinforced composites, emphasizing the novelty through systematic analysis of manufacturing techniques, fiber-matrix compatibility factors, and performance optimization strategies. The manuscript provides an in-depth analysis of NFRC mechanical properties and the influence of critical parameters, including filler content, moisture absorption, and fiber surface treatments, on performance characteristics. Furthermore, this review elucidates innovative processing techniques for commonly employed thermoplastic and thermoset resin systems, thereby facilitating informed matrix selection for targeted product development applications. Significantly, this work identifies and addresses key challenges confronting NFRC advancement while providing strategic perspectives and future outlooks for overcoming these limitations. The review outcomes encompass comprehensive understanding of sustainable manufacturing approaches, environmental benefits, and viable alternatives with substantial potential for future lightweight engineering applications across diverse industrial sectors.