The growing need for sustainable materials in various industries has driven research towards eco-friendly biopolymer composites. In this study, lignin microfillers were integrated into PHBV/modified bast fiber matrices, offering a promising solution for sustainable material innovation with improved performance and functionality. Nonwoven bast fiber mats were initially treated with propionic, succinic, and maleic anhydrides, evaluated through weight gain analysis, chemical characterization, thermal stability, and wettability assessments. These modified bast fibers were then reinforced with poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) biopolymer at 30 % loading using specialized molding techniques. The resulting biocomposites were subjected to comprehensive characterization, including moisture related properties, mechanical strength, thermal behavior, and fracturographical properties. In a final stage, lignin microparticles (LMPs) as biofillers were integrated at 1 %, 3 %, 5 %, and 7 % concentrations to enhance biocomposite properties. Experimental findings highlighted succinylated bast fibers as offering the greatest improvements in mechanical strength, thermal stability, and morphological integrity among the modified fibers. At an optimal 5 % lignin microfiller content, the biocomposites exhibited superior wettability and improved stiffness. However, excessive lignin loading led to particle agglomeration, diminishing overall performance. Fracturographical analysis provided insights into the fracture behavior of the biocomposites, highlighting the cohesive and interfacial characteristics of the materials under stress conditions. This research highlights the efficacy of sequential modification strategies in developing high-performance sustainable materials tailored for diverse industrial applications.
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