In this study, a biodegradable, cheap and durable recycled high-density polyethylene (rHDPE) polymer reinforced with rice husk (RH) fibre was fabricated into a foam structure through several processes, including extrusion, internal mixing and hot pressing. The effect of filler loading on the properties of the foam and the influence of RH surface treatments on the filler–matrix adhesion and mechanical properties of the composite foam were investigated. The morphological examination shows that 50 wt.% filler content resulted in an effective dispersion of cells with the smallest cell size (58.3 µm) and the highest density (7.62 × 1011 sel/cm³). This small cell size benefits the mechanical properties. Results indicate that the tensile strength and the Young’s modulus of the alkali-treated RH/rHDPE composite foam are the highest amongst the treatments (10.83 MPa and 858 MPa, respectively), followed by UV/O₃, which has shown considerable increments compared with the untreated composite. The flexural and impact tests also show the increment in strength for the composite foam after chemical treatment. Although the UV/O₃ surface treatment has minor influence on the mechanical enhancement of the composite foam, this method may be a reliable surface treatment of the fibre-reinforced composite.

Over the last few decades, processing and compatibility have become challenging and interesting investigation areas of polymer matrix nanocomposites. This study investigated the addition of maleic anhydride (MAH) at different ratios with graphene nanoplatelets (GnPs) in poly(lactic acid)/modified natural rubber/polyaniline/GnP (PLA/m-NR/PANI/GnP) nanocomposites via two processing methods: a two-step technique and a one-pot technique. The former technique involved first preparing a master batch of PLA grafted with MAH, followed by a second step involving the melt blending of the nanocomposite (T1) using MAH-g-PLA. On the other hand, the one-pot technique involved the direct mixing of MAH during the melt-blending process (T2). The mechanical, morphological and thermal properties of the prepared nanocomposites were investigated. The findings showed that adding MAH significantly improved the tensile strength and elongation at break by about 25% for PLA/m-NR/PANi/GnP nanocomposites, with an optimal ratio of 1:1 of MAH-g-PLA to GnP loading using the T1 technique. FTIR analysis confirmed the chemical interaction between MAH and PLA for T1 nanocomposites, which exhibited improved phase morphology with smoother surfaces. MAH-compatibilized nanocomposites had enhanced thermal stabilities when compared to the sample without a compatibilizer. The findings show that the compatibilized PLA nanocomposite is potentially suitable for bio-inspired materials.