<![CDATA[The automotive industry increasingly demands sustainable, multifunctional materials for interior components to simultaneously reduce environmental impact and improve occupant comfort. This study presents a comprehensive experimental validation of a coconut frond fibre-reinforced composite prototype intended for automotive door trim panel application. The prototype, developed at Technology Readiness Level (TRL) 2, was evaluated across three critical performance domains: mechanical properties (tensile, flexural, impact, and hardness), acoustic performance (sound absorption coefficient), and thermal characteristics (thermal conductivity and heat deflection temperature). Specimens were prepared and tested in accordance with internationally recognised standards (ASTM D3039, D790, D256, D2240, E1050, E1530, D648). Mean and standard deviation from five replicate specimens per test revealed tensile strength of 28.0 ± 1.4 MPa, flexural strength of 48.1 ± 0.8 MPa, impact toughness of 7.59 ± 0.54 kJ/m², and Shore D hardness of 69.4 ± 1.1. Acoustic evaluation yielded a Noise Reduction Coefficient (NRC) of 0.37 ± 0.01, with a peak absorption coefficient of 0.53 at 1000 Hz, significantly outperforming conventional ABS and PP interior materials. Thermal conductivity was measured at 0.142 ± 0.003 W/mK, which is lower than commercial ABS, while the heat deflection temperature of 93.0 ± 0.9°C exceeds the maximum cabin operating temperature of 85°C. All 11 evaluated parameters met or exceeded their respective automotive-grade target specifications, confirming TRL 3 achievement and suitability for advancement to TRL 4 environmental validation. Scanning electron microscopy (SEM) analysis revealed moderate fibre–matrix interfacial bonding with fibre pull-out as the dominant failure mechanism. The findings establish a robust technical database for the future scale-up and industrial adoption of this bio-based composite.]]>
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