This study investigates the reuse of mechanically recycled polyester–glass thermoset scraps (PS) as fillers in LDPE and HDPE matrices at 10–50 wt.% loading. Composites were produced through mechanical size reduction, single-screw extrusion, and compression molding without compatibilizers, and their mechanical and microstructural properties were systematically evaluated. LDPE composites exhibited a notable stiffness increase, with tensile modulus rising from 318.8 MPa (neat) to 1245.6 MPA (+291%) and tensile strength improving from 9.50 to 11.45 MPa (+20.5%). Flexural performance showed even stronger reinforcement: flexural modulus increased from 0.40 to 3.00 GPa (+650%) and flexural strength from 14.5 to 35.6 MPa (+145%). HDPE composites displayed similar behavior, with flexural modulus increasing from 1.2 to 3.1 GPa (+158%) and strength from 34.1 to 45.5 MPa (+33%). Surface-treated fillers provided additional stiffness gains (+36% in sPL4; +33% in sPH3). Impact strength decreased with loading (LDPE: −51%, HDPE: −61%), though surface treatment partially mitigated this (+14–19% in LDPE; +13% in HDPE). Density increased proportionally (PL: 0.95 → 1.20 g/cm3, PH: 0.99 → 1.23 g/cm3), while moisture uptake remained low (≤0.25%). Optical and SEM analyses indicated increasingly interconnected fiber networks at high loadings, driving stiffness and fracture behavior. Overall, PS-filled polyolefins offer a scalable route for converting thermoset waste into functional semi-structural materials.
Kasim et al. (Fri,) studied this question.