Total Filler Loading Research Articles

Learning based model for predicting mechanical properties and sustainable filler band for NBR composites using lignin and carbon black

Experimental determination of mechanical properties of rubber composites, such as tensile strength and hardness, involves complex multistage preparation procedures that are laborious and expensive. In this study, a hybrid filler of carbon black (CB) along with a sustainable filler of lignin is added for reinforcement in the nitrile butadiene rubber (NBR) matrix, with the total filler content varying from 10 parts per hundred rubber (phr) to 80 phr. This work aims to develop a data-driven predictive model for the mechanical properties of rubber composites. An artificial neural network (ANN) model using multilayer feed-forward back-propagation has been created to forecast the tensile strength (Ts) and hardness (Hd) of rubber composites. The model predicts the uniaxial tensile response and hardness using input parameters that include total filler and lignin loading levels. The effectiveness of the suggested prediction method was demonstrated by statistical analysis using confidence intervals, showing a prediction error between 5.47% and 3.23% for the Ts and between 3.03% and 1.85% for Hd at 95% confidence intervals. A sustainable green band could be defined in the developed model, which is handy for designers to replace CB with lignin in various NBR based products, such as hoses, seals, etc., without compromising on tensile strength and hardness.

Fluorographene and carbon nanotubes fillers reinforced nitrile butadiene rubber with enhanced mechanical, wear and oil resistant properties

AbstractIn this work, we prepared nitrile butadiene rubber (NBR) composites with fluorographene (FG) and carbon nanotubes (CNTs) as hybrid fillers by a solution‐blending method. The resulting composites xFG/yCNTs‐NBR, where x and y represent the loading of FG and CNTs respectively, show significantly improved physical and mechanical properties. The hybrid fillers can form a filler network in the rubber matrix, leading to efficient energy dissipation. As a result, when the mass ratio of FG to CNTs is 1:1 and the total filler loading is 20 phr, the tensile strength of 10FG/10CNTs‐NBR is as high as 12.1 MPa. Furthermore, due to inherent lubricating and oil‐repelling effects of FG, 10FG/10CNTs‐NBR shows an abrasion resistance index (ARI) of 187% and a volume change of 2.38% after 72 h of soaking in aviation oil, which are 24% higher and 48% lower than the corresponding values of unfilled NBR composites, respectively. These results indicate that the hybrid fillers can effectively enhance the mechanical, wear and oil resistant properties of the elastomer composites, which is conductive for application of the NBR‐based composites.

Enhanced Thermal Conductivity of Epoxy Composites Fabricated with Boron Nitride and Multi-Walled Carbon Nanotubes

Preparation of polymer-based packaging materials with rapid heat dissipation capacity is crucial for ensuring high-power equipment’s service life. To achieve this, boron nitride (BN) and multi-walled carbon nanotubes (MWCNTs) were used in different ratios to prepare thermally conductive epoxy composites. These composites were created through a simple mixing and curing process, resulting in a heat transmission path. Then, BN and MWCNTs were separately functionalized with dopamine and acid to enhance their dispersibility and interfacial compatibility within the epoxy resin. This was done to further explore their influence on the formation of serial heat transfer pathways. The BN/MWCNTs/epoxy composites with a filler ratio of 15:1 and a total filler loading of 30 wt % exhibited a thermal conductivity of 0.92 W/mK, which is 118% higher than pure epoxy. These composites also displayed favorable mechanical properties and thermal stability. This study provides guidance for designing high-performance epoxy composites to meet modern electronic devices’ thermal management requirements.

Effect of monodisperse mesoporous bioactive glass spheres (MBGs) on the mechanical properties and bioactivity of dental composites

Secondary caries is one of the main reasons for the failure of dental resin composites, and adding bioactive fillers such as bioactive glass and amorphous calcium phosphate to the resin composites has been proved to be an effective solution for this problem. In the present study, we investigated the effect of monodisperse mesoporous bioactive glass spheres (MBGs) we prepared on the mechanical properties and bioactivity of dental resins. The results revealed that compared with traditional bioactive glass (BG), MBGs fillers significantly enhanced the mechanical properties of the dental resin composites, whether they were added alone or as functional fillers together with nonporous silica particles. The dental resins filled with bimodal fillers (mass ratio of MBGs: nonporous silica = 10:50, total filler loading 60 wt%) exhibited the best mechanical performance. Their flexural strength was 37.66% higher than the samples with BG at the same filling proportion. Furthermore, the prepared MBGs possessed excellent monodispersity and sufficient apatite formation performance, and the biocompatibility of the composites were also improved by MBGs fillers. These suggest the potential use of the prepared MBGs as multifunctional fillers for the improvement of the performance of dental resins.

Fabrication of wear-resistant PA6 composites with superior thermal conductivity and mechanical properties via constructing highly oriented hybrid network of SiC-packed BN platelets

Herein, a strong extensional and shearing field was introduced to construct highly oriented hybrid networks of silicon carbide (SiC)-packed boron nitride (BN) platelets to fabricate high-performance wear-resistant PA6 composites. Results show that in-plane and through-plane thermal conductivity (TC) of the prepared PA6 composites with a total filler loading of 20 wt.% reached 1.31 and 0.35 W/(m K), 352% and 25% higher than those of pure PA6, respectively. It is attributed to the highly oriented hybrid network that facilitates the formation of efficient thermal conductivity pathways. Temperature monitoring results during friction confirm that high TC favors the friction heat dissipation performance. Meanwhile, the yield strength of PA6 composites increased by 39.1% and they still have excellent ductility with an elongation at break of 207.1%. Finally, the wear rate of PA6 composites decreased sharply by 92.5%. This method can be used to manufacture advanced linear bearing and guideway parts, etc.

3‐Octanoylthio‐1‐propyltriethoxysilane functionalized silica/rubber composites for application in tire: Structure, performance and synergism

AbstractIncreasing the polymer‐filler interaction is a challenge to develop high performance rubber composites. In this study, a new blocked mercaptosilane (3‐Octanoylthio‐1‐propyltriethoxysilane) was used to increase the rubber‐silica interaction by modifying highly dispersible silica and fumed silica surface with this silane. A two‐step process was used for the modification. Successful hydrolysis and condensation reaction was proved by Fourier‐transform infrared spectroscopy. Grafting density and grafting percentage were determined using thermogravimetric analysis. The modified silica/rubber composites were compared with the compositions where silane was separately added during mixing. Dynamic modulus versus strain signatures demonstrated strong polymer‐filler interaction after functionalization of the silica surface. The composites containing modified silica demonstrated improved mechanical properties and abrasion resistance over the unmodified one, which were correlated with the dispersion index. Dynamic mechanical analysis showed 28% improvement of rolling resistance and 67% improvement of ice traction after modification. Amount of silane modified silica also varied in total filler loading for precipitated silica/rubber composites. Silica‐rubber composites, where hybrid silica structure (75/25 modified and pristine silica ratio) was used, displayed interesting property to fulfill the requirement of green tire composites. Such a finding can be extended to developing tires for energy efficient vehicles.

Preparation of Ca doped wrinkled porous silica (Ca-WPS) for the improvement of apatite formation and mechanical properties of dental resins

The purpose of this work was to fabricate and characterize Ca doped wrinkled porous silica (Ca-WPS), and evaluate their effect on the mineralization and mechanical properties of resin composites as functional fillers. Ca-WPS were prepared by sol-gel method and characterized by scanning electron microscopy, transmission electron microscopy and N2 adsorption–desorption measurements. The mineralization properties of the prepared Ca-WPS particles and the resin composites with different amount of Ca-WPS were evaluated by simulated body fluid (SBF) immersion method. The mechanical properties (flexural strength, flexural modulus, compressive strength and microhardness) of the dental resins containing unimodal Ca-WPS fillers and bimodal Ca-WPS fillers with nonporous silica were evaluated by a universal testing machine. Results showed that after immersing in SBF for 5 d, apatite formed on the surface of Ca-WPS and composites containing Ca-WPS fillers, indicating the excellent mineralization property of the prepared Ca-WPS. The mechanical properties of the dental resins increase with the increase of the proportion of unimodal Ca-WPS fillers. The dental resins with bimodal Ca-WPS fillers showed better mechanical properties than the group with only nonporous fillers at the same filler loading (60 wt%). Among all the samples, the dental composites filled with bimodal fillers (mass ratio of Ca-WPS: nonporous silica = 10:50, total filler loading 60 wt%) exhibited the best mechanical performance. The flexural strength, flexural modulus, compressive strength and microhardness of these samples were 26.96%, 42.75%, 16.04% and 54.1% higher than the composites with solid silica particles alone, respectively. Thus, the prepared Ca-WPS could effectively improve the apatite formation and mechanical properties of resin composites.

Double-filler composite sulfonated poly(aryl ether ketone) membranes with graphite carbon nitride and graphene oxide as polyelectrolyte for fuel cells

Composite polymer electrolyte membranes are exhibiting their bright prospect especially in the field of fuel cell now. We prepared a series of double-filler composite proton exchange membranes from sulfonated poly(aryl ether ketone)s (SPAEK), graphene oxide (GO) and graphite carbon nitride (g-C3N4) with the total filler loading of 0.75 wt%. Facile solution blending provides homogeneous, strong and flexible composite SPAEK/GO/g-C3N4 membranes readily. Characterizations and measurements including membrane morphology, water absorption and dimensional swelling, thermal and mechanical properties, chemical and electrical performance are investigated in detail. Both GO and g-C3N4 nano-fillers can offer extra proton hopping sites via the H2N…HO3S interactions and hydrogen bond networks, which promote the proton conduction and membrane stability. Attributing to the interactions between the two nano-fillers and their interactions with SPAEK polymers, the double-filler compositing system exhibits better physicochemical stability, higher proton conductivity than the corresponding single-filler ones. The SPAEK/GO/g-C3N4(2/2) membrane shows the proton conductivity of 228 mS/cm@90 °C and power output of 675 mW/cm2@80 °C in a H2/O2 fuel cell. This work provides a significative way in the development of multi-component composite polymer electrolyte membranes applied for fuel cells.

Electrically conductive polymer composite containing hybrid graphene nanoplatelets and carbon nanotubes: synergistic effect and tunable conductivity anisotropy

Pristine carbon nanotubes (CNTs) and functionalized carbon nanotubes (f-CNTs) were introduced into conductive poly(methyl methacrylate)/graphene nanoplatelet (PMMA/GNP) composites to achieve a synergistic effect in the enhancement of the conductivity and the reduction in the percolation threshold by forming a 3-Dimensional(3-D) hybrid structure. Both the in-plane and perpendicular electrical properties were investigated. The synergies of hybrid fillers in the in-plane direction were more dependent on the total filler loading, while those in the perpendicular direction were significantly influenced by the GNP/CNT or GNP/f-CNT ratios. Typically, a schematic diagram of the evolution of the 3-D conductive pathways of PMMA/GNP/f-CNT composite at different GNP/f-CNT ratios was presented to explain this phenomenon. Moreover, tunable conductivity anisotropy (defined as the ratio of in-plane conductivity to perpendicular conductivity) ranging from 0.01 to 1000 was achieved, simply by constructing different conductive structures at various filler loadings or ratios in composites.Graphical abstractThe synergistic effect of GNPs and f-CNTs varies with the microstructural conductive network evolution at different filler ratios.

Thermal synergistic effect in hybrid filler epoxy composites consisting of graphene nanoplatelets and SiC particles

The use of hybrid filler is a promising strategy for development of thermally conductive polymer composites. This paper reported the measurement of thermal conductivity of the epoxy composite filled with a hybrid filler of graphene nanoplatelet (GNP) and silicon carbide (SiC) microparticles. For this hybrid filler, the effect of the average size of SiC on composite thermal conductivity was examined. The results showed that the thermal synergistic effect was highly affected by the average size of the SiC. By using a hybrid filler of 11% vol. GNP and 9% vol. 1 µm-size SiC micro-particles thermal conductivity has reached 3.44 W m−1 K−1. This value is 42% higher than the thermal conductivity of pure GNP composite at the same total filler loading. Moreover, additional experimental and theoretical analyses were performed to more explicitly understand the mechanism of thermal synergistic effect. It was shown that the synergistic effect between GNP and SiC is attributed to the more effective formation of thermally conductive pathways through the composite. Our results elucidate the mechanism of the thermal synergistic effect and providing information on hybrid filler design to achieve further improvement in the thermal conductivity of polymer composites.

Hybrid Electrically Conductive Adhesive (HECA) Properties as a Function of Hybrid Filler Ratio with Increasing Total Filler Loading

This paper presents a study on Hybrid Electrically Conductive Adhesive (HECA) properties as an in-depth analysis regarding hybrid filler ratio at low filler range. It is well established that the hybridization approach exhibits excellent functional properties of HECA. Still, the highest potential ability of the proposed HECA concerning relative amounts of involving fillers is the least being discovered. In this work, silver micro-flake (AgMF) and multiwalled carbon nanotube (MWCNT) conductive fillers were incorporated from 3 to 15 wt.%, while AgMF: MWCNT filler ratio is varied between 0.006 up to 0.2 to choose the best combination. Here, a planetary centrifugal mixer with different mixing time and sequence were considered to identify the most effective mixing method. The functional properties of HECA were characterized in terms of a four-point probe electrical test and a lap shear test via tensile mode. The morphological study suggests that a shorter centrifugal mixing period allows an adequate dispersion of the micro-nano fillers in the HECA system and revealed superior interfacial bonding between the fillers at the optimum ratio. Interestingly, electrical resistivity at critical concentration showed an optimum ratio by incorporating only 2.5% AgMF in the hybrid fillers to yield a 42.62% reduction. However, the significant effects of hybridization are observed until the percolation threshold of HECA at 9 wt% only, followed by a 38.5% reduction beyond this limit. Moreover, the lap shear strength is most reliable at a total filler of 6 wt%, an indication of an excellent filler-binder load distribution.

Co/multi-walled carbon nanotubes/polyethylene composites for microwave absorption: Tuning the effectiveness of electromagnetic shielding by varying the components ratio

We present novel polyethylene (PE) composites for electromagnetic interference (EMI) shielding application. They are based on cobalt modified multi-walled carbon nanotubes (MWCNTs) produced via in situ polymerization of ethylene, with the Ti-Ziegler–Natta catalyst preliminarily immobilized on Co/MWCNT hybrids. The electromagnetic properties of the composites were tuned by varying the filler loading and Co:MWCNT ratio. The microstructure of the composites and electromagnetic absorption process were carefully characterized by transmission and scanning electron microscopy, X-ray diffraction, vibrating sample magnetometry, ferromagnetic resonance and vector network analysis. The electromagnetic wave absorbing properties of the nanocomposite were investigated in the 10 MHz−18 GHz frequency range revealing that the EMI absorption properties can be tuned by varying the Co:MWCNT weight ratio in the filler. Interestingly, the Co/MWCNT-PE composite with a total filler and Co loading of only 12 and 1.7 wt%, respectively, showed extremely high reflection loss (RL) of −55 dB. More importantly, an effective bandwidth of 12.8–17.8 GHz (RL below −10 dB) was achieved for a matching thickness of only 1.5 mm. The specific RL value (RL/filler loading) of the composite was superior in comparison with the previously reported nanostructured carbon materials. The highly effective absorbing properties of Co/MWCNT-PE composites are explained primarily by the unprecedented uniform filler distribution in the polyethylene as well as by the synergistic effect of MWCNTs and Co nanoparticles. This approach thus offered an effective strategy to design cost-effective, lightweight and flexible EMI shielding materials with tunable dielectric and magnetic performance.

Mechanical properties of silica fume reinforced epoxy glass microballoons syntactic foams

Silica fume, a by-product obtained during the smelting process of silicon and ferrosilicon alloys, is widely used as a filler material in concrete for construction purposes. This study discusses the use of silica fume (1–7% v/v) as novel fillers in epoxy glass microballoon syntactic foams. The total filler loading i.e. glass microballoons and silica fume is maintained at 40% (v/v). Epoxy syntactic foams are popularly being used in the construction industry for the fabrication of light-weight materials in the sandwiched configuration. The use of silica fume is expected to improve the mechanical properties of such syntactic foams, which otherwise suffer due to the incorporation of hollow glass microballoons. As expected, the incorporation of silica fume enhanced the mechanical properties of the base syntactic foam. Epoxy glass microballoons reinforced with silica fume (5% v/v) increased the specific tensile strength by ∼ 47 percent, flexural strength by ∼ 54 percent and compressive toughness by ∼ 23 percent, etc. The increase in properties is attributed to the homogenous dispersion of the silica fume throughout the matrix and the load-bearing ability of silica fume. The use of silica fume opens up vistas in the field of polymer syntactic foams.

Polymerization shrinkage behaviour of resin composites functionalized with unsilanized bioactive glass fillers

Previous work has shown that partial replacement of reinforcing fillers with unsilanized silica particles can diminish polymerization shrinkage stress of dental resin composites. The aim of the present study was to investigate whether such an effect can be attained by using unsilanized bioactive glass (BG). Incorporating BG fillers into resin composites is interesting due to their potential for exerting caries-preventive effects. Experimental light-curable composites with a total filler load of 77 wt% were prepared. Reinforcing fillers were partially replaced with 0–60 wt% of BG 45S5 and an experimental low-sodium fluoride-containing BG. The following properties were investigated: linear shrinkage, degree of conversion, shrinkage stress, maximum shrinkage stress rate, and time to achieve maximum shrinkage stress rate. The diminishing effect of BG 45S5 on shrinkage stress was mediated by a decrease in degree of conversion caused by this BG type. In contrast, as the degree of conversion remained unaffected by the experimental BG, the resulting shrinkage behaviour was governed by the effect of varying amounts of silanized and unsilanized fillers on material’s viscoelastic properties. The replacement of silanized reinforcing fillers with unsilanized BG did not reduce polymerization shrinkage stress unless the reduction was attained indirectly through a diminished degree of conversion.

Bridging boron nitride nanosheets with oriented carbon nanotubes by electrospinning for the fabrication of thermal conductivity enhanced flexible nanocomposites

With the rapidly growing power density of integrated circuits in modern electronic devices, how to construct efficient thermal conductive network achieving advanced heat conduction materials has attracted widespread attention. In this work, at an extremely low content of carbon nanotubes (CNTs), a synergistic hybrid structure of bridged boron nitride nanosheets (BNNSs) by CNTs was constructed along the polyvinyl alcohol (PVA) fibers by electrospinning, and simply resin transfer molding method was employed to produce Epoxy/PVA (BNNSs/CNTs) composite film. Fabricated Epoxy/PVA (BNNSs/CNTs) composite film not only presented great in-plane thermal conductivity (TC) 6.3 W/m·K at total filler loading of 27.5 wt%, higher than that of Epoxy/PVA (BNNSs) composite film without CNTs by 88%, but also exhibited excellent electrical insulating properties (6 × 10−13 S/cm). During the heating and cooling test, infrared thermal images showed that the synergistic hybrid composite has the highest surface temperature and the best heat dissipation capacity compared to other samples. The great TC enhancement is due to the bridging BNNSs by CNTs reducing interfacial thermal resistance between neighboring fillers. Additionally, good mechanical properties and stable TC provide more immense potential for the wide application of new generated flexible thermal management materials.

Curing potential of experimental resin composites filled with bioactive glass: A comparison between Bis-EMA and UDMA based resin systems

ObjectivesTo evaluate the degree of conversion, light transmittance, and depth of cure of two experimental light-curable bioactive glass (BG)-containing composite series based on different resin systems. MethodsExperimental composite series based on either Bis-EMA or UDMA resin were prepared. Each series contained 0, 5, 10, 20, and 40wt% of BG 45S5. Reinforcing fillers were added up to a total filler load of 70wt%. The degree of conversion was evaluated using Raman spectroscopy, while light transmittance was measured using visible light spectroscopy. The depth of cure was estimated from the degree of conversion data and using the ISO 4049 scraping test. ResultsReplacement of reinforcing fillers with BG can diminish the degree of conversion, light transmittance, and depth of cure. The effect of BG on the aforementioned properties was highly variable between the experimental series. While in the Bis-EMA series, the degree of conversion was significantly impaired by BG, all of the composites in the UDMA series attained clinically acceptable degree of conversion values. The reduction of the degree of conversion in the Bis-EMA series occurred independently of the changes in light transmittance. The UDMA series showed better light transmittance and consequently higher depth of cure than the Bis-EMA series. The depth of cure for all composites in the UDMA series was above 2mm. SignificanceWhile the Bis-EMA series demonstrated clinically acceptable curing potential only for 0–10wt% of BG loading, an excellent curing potential in the UDMA series was observed for a wide range (0–40wt%) of BG loadings.

In situ synthesis of graphene oxide in multi-walled carbon nanotube hybrid-reinforced polyetherimide nanocomposites with improved electrical, mechanical and thermal properties

The assembling of two carbonaceous nanomaterials to fabricate 3D hierarchical graphene-carbon nanotube hybrid is the superlative strategy to synergistically impart electrical and mechanical properties to polymers. In the present study, we have evaluated the effects of nanoscale hybridization of graphene oxide (GO) and multi-wall carbon nanotube (MWCNT) on the electrical, mechanical and thermal properties of polyetherimide (PEI) nanocomposites reinforced by GO-MWCNT hybrid. Synthesis of GO-MWCNT hybrid was confirmed by various spectroscopic measurements. The inclusion of GO-MWCNT hybrid to PEI endows optimum dispersion and better interfacial interactions between GO-MWCNTs and PEI matrix and thus remarkably improved the conductivity, tensile properties and thermal stability of PEI. When the mass ratio of GO to MWCNT is 1:1 and the total filler loading is only 2 wt%, the DC conductivity of the nanocomposite films enhanced by 6 orders of magnitude, the tensile strength increased by fourfold and the Young’s modulus increased by sixfold compared to those of pure PEI. The reinforcement efficiency of the GO-MWCNT (1:1) hybrid in terms of the modulus of the nanocomposite was predicted using modified Halpin–Tsai modelling and compared with the experiment results. The present PEI nanocomposite materials could significantly fulfil the demands raised by the aerospace community.

Conductive silicone elastomers electrodes processable by screen printing

Conductive inks consisting of graphene and carbon black conductive fillers into a polydimethylsiloxane (PDMS) matrix, which can be processed into thin films by screen printing are developed. The influence of filler composition and content on mechanical and electrical properties of the conductive composites is investigated. The best composites were evaluated as electrode material for dielectric elastomer actuators and for piezoelectric sensors. With increasing filler content, the electrical properties of the resulting composites of graphite nanoplates (GNPs) or a binary mixture of GNPs and carbon black (CB) with PDMS (Mw = 139 kg/mol) are enhanced. Hence, PDMS composites filled with GNPs (42 wt.%) or a binary mixture of GNPs/CB (300/150 ratio, 30 wt.% of total filler loading) exhibited constant contact resistance values of 0.5 and 5 Ω determined in life-cycle test, respectively, thus rendering them suitable as electrode materials for piezosensors. On the other hand, dielectric elastomer actuators require more flexible electrode materials, which could be tuned by varying the polymer molecular weight and by reducing the filler content. Therefore, a composite consisting of PDMS (Mw = 692 kg/mol) and a binary filler mixture of GNPs/CB (150/75 ratio, 18 wt.% of total filler loading) was used for producing the electrodes of dielectric elastomer transducers (DETs). The produced DETs with different electrode thicknesses were characterized in terms of their performance. The negligible hysteresis of the electrode materials is favorable for sensor and actuator applications.

Thermal and electrical conductivity control in hybrid composites with graphene and boron nitride fillers

We report on the thermal and electrical properties of hybrid epoxy composites with graphene and boron nitride fillers. The thicknesses, lateral dimensions, and aspect ratios of each filler material were intentionally selected for geometric similarity to one another, in contrast to prior studies that utilized dissimilar filler geometries to achieve a ‘synergistic’ effect. We demonstrate that the electrically-conductive graphene and electrically-insulating boron nitride fillers allow one to effectively engineer the thermal and electrical conductivities of their resulting composites. By varying the constituent fraction of boron nitride to graphene in a composite with ∼44% total filler loading, one can tune the thermal conductivity enhancement from a factor of ×15 to ×35 and increase the electrical conductivity by many orders of magnitude. The obtained results are important for the development of next-generation thermal interface materials with controllable electrical properties necessary for applications requiring either electrical grounding or insulation.

Mechanical particle size reduction methods as potential interfacial optimization alternative for a low-carbon particulate reinforced marine bio-composite

The materials particle size reduction is an efficient, but often a time and energy intensive operation. Targeting the optimization of composite manufacturing process through low-cost materials selection, production efficiency, and minimization of energy consumption, this study investigated two dry particle size reduction methods –slow grinding and fast collision milling– as a potential one-step non-chemical filler/matrix compatibilization alternative, for a Marine/Polypropylene Bio-composite sheet material, for building applications. Two local coastal litter materials from Sydney, kelp brown algae (Ecklonia spp.) and bivalve mollusc seashell (Verenidae spp.) were selected as combined multi-functional bio-fillers. Four bio-composites prototypes were manufactured by isothermal hot-compression method, formulated to represent the most relevant permutations of the powders, with filler/matrix 60/40 wt%, respectively. Mixed wood waste sawdust was incorporated as secondary reinforcement to the blend, as a third of the total filler load. 20 specimens were prepared and tested. The effect of the size reduction methods on the particles properties were characterized by bulk, and surface sensitive qualitative and quantitative analyses. The surface roughness, wettability, fracture surface, and mechanical properties of the bio-composite prototypes are reported. The overall results indicated four distinctive filler morphologies were obtained: laminar, flakes, slabs, oblong particles, in which the physicochemical properties, topographical properties, and crystal structure greatly differed. The prototype panels manufactured with mechanically milled powders presented the peak mechanical properties for flexural strength, attributable to an enhanced materials interfacial behaviour. Additionally, as result of the different powder properties, competitive advantages were attained for moisture resistance and appearance grade, thus as potential candidates for architectural interior applications.