Abstract The inherent incompatibility between hydrophilic lignocellulosic fibers and hydrophobic thermoplastic matrices in wood-plastic composites (WPCs) creates significant interfacial bonding challenges that compromise mechanical performance and durability. This study aimed to provide a critical analysis of current trends in WPC development with particular emphasis on the effects of various binder systems on the properties of the resulting WPCs. Binders can be classified based on both chemical nature (thermoplastic, thermosetting, biopolymer, and inorganic/geopolymer) and functional mechanisms (coupling agents vs. compatibilizers), providing an extensive framework for optimal selection. Extrusion dominates industrial production due to cost-effectiveness, while injection moulding offers superior design flexibility. Mechanical property investigations confirmed that appropriate coupling agents, particularly maleated polyolefins, significantly enhance tensile strength, flexural strength, and impact resistance by bridging the compatibility gap between matrix and filler. Thermal studies demonstrated that binder selection directly influences thermal stability, with PVC-based systems showing superior heat resistance compared to polyethylene variants. Morphological analyses revealed that effective binders promote uniform filler dispersion and eliminate interfacial voids, resulting in improved stress transfer mechanisms. This study establishes a foundation for developing next-generation WPCs that balance sustainability goals with enhanced performance characteristics.
Adeyanju et al. (Tue,) studied this question.