Characterization of Bio-Epoxy Composites with Mussel Shell Powder and Posidonia Fibers

Bio-epoxy composites were fabricated by casting a resin–hardener–filler mixture into 3D-printed molds, using different sea-originated secondary raw materials: mussel shell powder (MSP) (63–83 μm) and Posidonia oceanica short fibers (POF) (1–2 mm). Monofiller composites were prepared with 5 or 10 wt.% MSP, or 5 or 10 wt.% POF. Hybrid formulations were also produced, containing both MSP and POF in two combinations, where the total amount of filler again summed up at 10 wt.%. A subset of the samples was conditioned by immersion in a 35 ‰ NaCl solution reproducing seawater composition until saturation was reached. Characterization was carried out on unconditioned and conditioned samples by Shore D hardness and Charpy impact tests while performing three-point flexural loading only on unconditioned ones. Fracture morphology was also investigated. Adding MSP slightly enhanced resin hardness, whereas impact absorption exhibited, to a variable extent, a two-phase behavior, reproducing crack initiation and propagation. The MSP6-POF4 hybrid configuration provided the greatest improvement in absorbed energy (25–30% higher), which was retained after conditioning. The introduction of fillers, first separately, then in combination, resulted in a reduction in flexural strength to a similar extent for all unconditioned configurations. Finally, composite panels containing 10 wt.% MSP, 10 wt.% POF, and a 6MSP–4POF hybrid formulation, intended for prospective boat deck applications, were fabricated and compared with neat bio-epoxy, showing satisfactory consolidation. Density and post-molding dimensional shrinkage were measured on the panels.