Polybenzoxazine (PBz) is a fantastic highly intriguing resin for various sophisticated uses. The current advances, properties, and progress in synthesizing bio-based polybenzoxazines and their use in coating applications are highlighted in this study.

Corrosion is a major issue in many industries, leading to material degradation, increased maintenance costs, and safety hazards. Conventional protective coatings frequently rely on hazardous chemicals, which has driven demand for environmentally friendly materials that can enhance the durability of infrastructure. The present study investigates the structural, mechanical, anticorrosive, and tensile properties of a novel polymer composite based on tannic acid-benzoxazine monomer (TA-BZ), reinforced with epoxy resin and zinc oxide (ZnO) nanoparticles. The composite formulations are designated as Epoxy-TA-BZ1-ZnO (A), Epoxy-TA-BZ2-ZnO (B), and Epoxy-TA-BZ4-ZnO (C). The objective of this research is to develop a sustainable material system with improved anticorrosive and mechanical performance. The composites were synthesized through the crosslinking of TA-BZ with epoxy resin and the incorporation of ZnO nanoparticles, known for their corrosion-inhibiting properties and contributions to tensile strength. The materials were evaluated using Fourier Transform Infrared (FT-IR) spectroscopy, Thermogravimetric Analysis (TGA), Differential Scanning Calorimetry (DSC), Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), potentiodynamic polarization techniques, and tensile testing. Among the tested formulations, Epoxy-TA-BZ4-ZnO exhibited outstanding anticorrosive performance, achieving a minimal corrosion rate of 0.06 mm/year. This performance is attributed to the favorable dispersion of ZnO nanoparticles at 5 wt%, which serve as effective barriers to corrosive agents under the conditions studied. These findings highlight the potential of TA-BZ-based composites as environmentally sustainable alternatives to conventional coatings in corrosion-sensitive applications.