International Journal of Scientific Research and Engineering Development

This study focuses on the sustainable recycling of discarded footwear waste into high-performance polymer composites through advanced chemical and nano-reinforcement techniques. The process involves shredding footwear waste and blending it with polymeric matrices consisting of approximately 60 wt% recycled footwear base material, 25 wt% polyurethane (PU), and 10 wt% styrene-butadiene rubber (SBR) to enhance flexibility and strength. To further improve mechanical performance, 5wt% nano-fillers comprising 3 wt% silica nanoparticles and 2 wt% carbon nanotubes (CNTs) are introduced, optimizing wear resistance and tensile strength. Interfacial bonding between the recycled matrix and polymer additives is enhanced using 2–3 wt% silane coupling agents and 1 wt% maleic anhydride-grafted polymer modifiers, resulting in improved load transfer and composite stability.The developed composites are processed using automated sorting, nano-enhanced material treatment, and smart extrusion-based manufacturing, yielding uniform, durable, and aesthetically customizable materials. The resulting products demonstrate superior mechanical integrity, making them suitable for footwear components, resilient flooring, and decorative elements. This innovative system embodies circular economy principles, minimizing waste, conserving resources, and contributing to eco-friendly material innovation within the footwear industry.