ABSTRACT The hand layup approach was used to fabricate epoxy-based hybrid polymer composites reinforced with biochar made from recycled rice husk and basalt fibers. The biochar, derived from recycled rice husk, served as a filler material to enhance the composite properties. E1 (0% biochar), E2 (2% biochar), E3 (5% biochar), and E4 (7% biochar), where the four samples with varied biochar percentage were made.The tensile strength increased from 45.2 MPa (E1) to 58.7 MPa (E3) in mechanical tests, demonstrating improved performance with a higher biochar content. Flexural strength peaked in E3 at 85.3 MPa, however filler agglomeration caused a minor drop in E4. Energy Dispersive Spectroscopy (EDS) and Field Emission Scanning Electron Microscopy was utilized to examine the surface morphology and dispersion of biochar within the composite matrix to assist in determining the elemental composition of the composites and their morphological properties.The compatibility of biochar with the polymer matrix was demonstrated by FTIR spectroscopy, which validated chemical interactions.These results highlight biochar’s potential as a sustainable filler material to improve environmental and mechanical performance. Strength and durability were balanced at the ideal biochar level of 5%, providing a route for the creation of high-performance, environmentally friendly composites appropriate for cutting-edge technical applications.
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