Flexural Performance of Unsaturated Polyester Composites Reinforced with Coconut Shell Charcoal Powder for Lightweight Structural Applications

Polymer-based composites have emerged as viable alternatives to metals for applications requiring reduced weight, corrosion resistance, and cost-effectiveness; however, their relatively low mechanical strength remains a significant limitation. This study evaluates the flexural performance of unsaturated polyester composites reinforced with coconut shell charcoal (CC) powder at filler contents of 0%, 10%, 20%, and 30% by weight, in accordance with ASTM D790. The incorporation of 20 wt% CC yielded the highest flexural strength of 132.43 MPa, representing a 153% improvement compared to pure polyester (52.10 MPa). Flexural modulus also increased substantially at this composition, indicating enhanced stiffness resulting from improved interfacial bonding and efficient stress transfer. In contrast, increasing the filler content beyond 20 wt% resulted in a reduction of up to 32% in strength, attributed to particle agglomeration and void formation. Overall, the results identify 20 wt% CC as the optimal reinforcement level, significantly improving energy absorption and bending resistance, thereby positioning this composite as a promising candidate for lightweight structural applications.