PurposeThe purpose of current study deals with the development and wear testing of jute and cotton fiber reinforced with nano fly ash-based epoxy composites. Performance of waste cotton fabric nano hybrid composites are compared with waste jute fabric nano hybrid composites.Design/methodology/approachBasic hand layup technique was used to develop composites. To optimize the parameters and design of experiments, Taguchi design was implemented to test wear rate and co-efficient of friction as per ASTM standards. Performance of waste cotton fabric nano hybrid composites is compared with waste jute fabric nano hybrid composites.FindingsResult shows that nano fly ash lowers the wear rate and co-efficient of friction in developed composites. Findings reveals that hybrid composites of waste jute Fabric with 3 Wt.% of nano fly ash performed best amongst all composites developed. Morphology of nano composites worn out surfaces are also analyzed through SEM.Practical implicationsPractically, textile waste, i.e. jute, cotton and nano fly ash (thermal power plant) all wastes, is used to develop composites for multi-function application.Social implicationsWastes are reused and recycled to develop epoxy-based composites for sustainable structures in aviation.Originality/valueTo the best of the authors’ knowledge, nano fly ash and jute, cotton combination is used for the first time to develop and test for wear application.