Hybridization, Microstructural Characterization, and Mechanical Properties of Sansevieria–echinatus Hybrid Composites

Sansevieria forskaoliana and echinatus fibers are abundant natural resources native to the central and western regions of Gondar, Ethiopia, and offer significant potential as sustainable reinforcement materials in polymer composites. This study investigates the mechanical and microstructural properties of hybrid Sansevieria/echinatus fiber‐reinforced polyester composites. The natural fibers were chemically treated with 5% and 10% sodium hydroxide (NaOH) solutions to remove surface impurities, reduce lignin content, and enhance interfacial bonding with the polyester matrix. Composite laminates were fabricated using the hand lay‐up technique followed by compression molding, with fiber weight fractions of 25, 30, 35, and 40 wt.% and different lamina stacking sequences (90/0/45, 0/45/90, and 45/90/0). The experimental design was developed based on the Taguchi method to evaluate the influence of processing parameters. Mechanical characterization, including tensile, flexural, and impact testing, revealed that the composite containing 35 wt.% hybrid fibers with a 90/0/45 lamina orientation exhibited the highest tensile strength (95.55 MPa) and impact strength (201.03 kJ/m 2 ). Microstructural analysis confirmed improved fiber–matrix adhesion and reduced fiber pull‐out at this optimal configuration. Overall, the hybrid composites demonstrated superior mechanical performance compared to single‐fiber composites and laminates with non‐optimal orientations. The results indicate that Sansevieria/echinatus hybrid fiber‐reinforced polyester composites possess enhanced strength and interfacial bonding characteristics, making them promising candidates for lightweight structural and load‐bearing applications.