The global demand for sustainable building materials has fuelled research into composite panels from wood waste. Despite their potential, the widespread adoption of this practice is hindered by the absence of quality standards, inconsistent material properties, and uncertainties about durability and strength. This paper critically reviews existing standards, manufacturing processes, and the suitability of panels from wood waste. A systematic review is conducted to identify the influencing processes and parameters affecting panel performance, from waste collection to the finishing stages. The findings indicate that incorporating 10–30% of wood waste can enhance the mechanical and physical properties, with particularly improved hygroscopic properties and greater dimensional stability. By establishing comprehensive standards and optimizing manufacturing processes, wood waste-based panels can emerge as a viable and eco-friendly alternative. Furthermore, the potential for repeated recycling in a closed-loop process offers promising environmental benefits, though it necessitates balancing resource conservation with product quality. By addressing these challenges, wood waste-based panels can significantly contribute to environmental conservation and resource management.

The utilisation of wood-processing residues in particleboard production provides an opportunity to improve resource efficiency. However, limited research has systematically examined the combined influence of material characteristics and fabrication parameters on panel performance. This study investigates the joint influence of particle mix, resin content and processing method on the performance of particleboards manufactured from radiata pine (Pinus radiata) wood residues. Single-layer panels were fabricated using coarse particles, thin particles, and a thin–fine particle blend at three resin contents via dry and water-conditioned fabrication methods, targeting a constant density of 600 kg/m³. Panels were evaluated for modulus of rupture (MOR), modulus of elasticity (MOE), thickness swelling (TS) and water absorption (WA). The results revealed statistically significant interaction effects among the factors, with particle geometry primarily governing bending performance, and fabrication route exerting the strongest influence on dimensional stability. Thin-particle panels exhibited the highest bending performance, with the 12 wt.% dry-fabrication method achieving an average MOE of 1862 MPa and MOR of 14.65 MPa. In contrast, fine-particle incorporation reduced bending performance but improved dimensional stability, with micro-CT analysis showing lower porosity and smaller pore features in the selected fines-containing panel, reaching a minimum porosity of 3.6%. Overall, the findings demonstrate that coordinated optimisation of material composition and processing parameters can enhance the performance of residue-based particleboards.