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With a focus on sustainable natural fiber reinforced polypropylene composites in varied industries like automotive and aerospace, this study investigates the impact of matrix modification and surface treatment of basalt fibers on the thermomechanical properties of basalt fiber reinforced heterophasic polypropylene composites. Polypropylene matrix modification was achieved by adding maleic anhydride grafted polypropylene (PP-g-MA), resulting in composites that exhibited a 133 % improvement in the tensile strength and 256 % improvement in the tensile modulus at 30 % fiber weight compared to neat polypropylene. The short basalt fibers underwent a silane treatment; However, the thermal treatment used to strip the default manufacturer's sizing resulted in a fluffy fibres texture, which led to agglomeration and feeding issues during processing. Although the silane treatment helped establish a better fiber-matrix interphase, no significant improvement in tensile strength was observed. However, the tensile modulus saw a 343 % improvement at 30 % fiber weight as compared to neat polypropylene. Resizing short basalt fibers following fiber recovery at the end-of-life stage of the composite would be challenging due to the fluffy nature of the fibers. Therefore, any fiber treatment should be done at the initial fiber manufacturing stage, and surface treatment at later stages requires detailed study.

Hybrid heterophasic polypropylene (PP) composites comprising basalt fibers and Magnesium oxysulfate reinforcements were fabricated for the next generation of automobile plastic parts. The prepared composites were tested and characterized for their thermo-mechanical performance. Addition of polypropylene-grafted-maleic anhydride (PP-g-MA) increased the tensile and flexural strength signifying the establishment of an adequate fiber-matrix interphase in case of hybrid composites. While basalt fiber addition played a reinforcing role in all the composites, Magnesium oxysulfate agglomeration and lack of an adequate fiber – matrix interphase reduced the reinforcing efficiency of the hybrid reinforcements at higher Magnesium oxysulfate contents. Nevertheless, the hybrid composites had higher mechanical properties than the neat polypropylene and Magnesium oxysulfate reinforced polypropylene. Hybrid composites offer enhanced mechanical properties, improved impact performance, and increased sustainability, making them a promising choice for the automotive industry.