This research explores the application of pistachio shell powder (PSP), an agro-waste product, as a bio-filler for polylactic acid (PLA) for the development of sustainable green composites using injection molding. The study utilizes Box-Behnken Design (BBD) to optimize prominent processing parameters, and the properties of the resultant composites are explored through Response Surface Methodology (RSM). The results indicate that the addition of PSP greatly affects the mechanical characteristics of PLA composites, with increasing percentages of fillers contributing to the enhanced tensile and flexural moduli but decreasing elongation and strength. Confirmation of the significant effects of PSP and machining conditions on composite properties is found in ANOVA results, which indicate the suitability of agro-waste fillers to improve the performance of green composites. These results set avenues for applications in biodegradable packaging material and ecologically friendly materials but require further investigation to tackle the batch to batch variability across seasons and regions.
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