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The integration of sabai grass fibers and fly ash in epoxy resin combines the strengths of both materials for developing a tailor-made composite laminate that balances performance, sustainability, and cost-efficiency. This innovative blend of natural fibers and industrial waste promotes environmental conservation. The laminates produced could also be used in diverse industrial and structural applications. This study investigated the mechanical properties of composite laminates reinforced with sabai grass fibers, fly ash filler, and epoxy resin as the matrix. In this work, the hand lay-up method was used to fabricate composites with two stacking configurations ((0°/0°/0°/0°) and (0°/90°/90°/0°)) and filler contents of 1.5 wt.%, 3 wt.%, and 5 wt.%. Various weight fractions of fly ash filler and sabai grass fiber were integrated into the epoxy resin to evaluate their impact on tensile strength, flexural strength, and hardness. The experimental results indicate that adding fly ash significantly improves the composite’s hardness to 27 HV in the composites containing 5 wt.% filler, while sabai grass fibers contribute to enhanced tensile strength and flexural strength. The composites with (0°/0°/0°/0°) fibers and 5 wt.% filler showed a higher tensile strength of 63.5 MPa and flexural strength of 118.5 MPa. The fractured sample was analyzed with the help of FESEM images. The XRD analysis confirmed the presence of fly ash components suitable for forming a bond with epoxy. EDX was conducted to determine the elemental composition of the fly ash. FTIR analysis verified the removal of impurities such as dust, dirt, and lignin from the fiber surface following NaOH treatment. Full article