Environmentally sustainable toughened nanocomposites based on recycled face masks and nitrile gloves

The COVID-19 pandemic has left a lasting environmental footprint, especially through the surge of single-use biomedical plastics such as disposable facemasks and nitrile gloves. Their improper disposal has created a new source of non-biodegradable waste, which fragments into microplastics and poses ecological and health hazards. This study establishes a sustainable recycling pathway by extracting polypropylene (PP) from discarded facemasks and nitrile butadiene rubber (NBR) from used gloves, and reinforcing them with Cloisite nanoclay to develop toughened nanocomposites. The incorporation of nanoclay significantly enhanced tensile strength, hardness, dielectric performance, and thermal stability, with optimum properties achieved at a 3.5% (by wt) loading. Structural and morphological investigations using FTIR, TGA, SEM, and AFM confirmed improved interfacial adhesion, uniform filler dispersion, and suppression of phase separation at this level. Beyond 3.5% (by wt) nanoclay, agglomeration effects reduced mechanical efficiency. The multifunctional nature of these composites makes them attractive for tribological applications, electrical insulation, and lightweight structural uses. Additionally, their compatibility with extrusion-based additive manufacturing provides scalability and adaptability to 3D printing of durable, customized components. This dual achievement of biomedical waste valorization and high-performance material development demonstrates a cleaner production strategy aligned with circular economy principles. Overall, the work not only offers a feasible solution to pandemic-related waste management but also establishes a pathway for developing sustainable, high-value nanocomposites with industrial relevance.