There has been an increase in research over the past decades into the use of environmentally friendly materials in brake pads, such as natural fibres. This is due to the possibility that natural fibbers could serve as an alternative to the noxious asbestos materials in tribological applications like brake pads. As a result, utilizing the compacting mould technique, an asbestos-free friction material was developed using agricultural waste (coconut shell and oil bean stalk) as a filler element, alongside aluminium dross, metal chip industrial wastes and carbon black. The filler material considered had particles as small as 300 μm, with epoxy resin serving as the binding agent. Using these waste materials can help reduce environmental pollution and the risk to animal and plant life (Preeti et al., Pharma Innov J 7:94–102, 2018; Sajib, A Study on the effects of environmental pollution on human life in the riverbank area of Barishal City Corporation (Kirtankhola River), 2021). This research aimed to replace asbestos in brake pads due to its carcinogenic nature, reducing the health risks associated with manufacturing and using these brake pads. The brake pad materials were cast and produced using square wooden moulds. Four samples were created, comprising the same mixing ratio but varying in reinforcement fibre and particle size, with epoxy resin used as the matrix. Various tests were conducted on these samples, including a water absorption test, specific gravity test, compressive strength test, hardness test, thermal conductivity, SEM and EDX. The developed brake pads underwent microscopic characterization and structural examination using a scanning electron microscope (SEM) fitted with energy-dispersive X-ray spectroscopy (EDX) for elemental characterization. Thermal conductivity was obtained using automated Lee’s Disc apparatus. Comprehensive strength analysis was conducted using a universal testing machine (UTM).The specific gravity tests yielded values for the developed composites in the range of 1.136–1.257, while the commercial brake pad had a value of 2.081, indicating that the produced samples were lighter and less dense. The water absorptivity of the developed samples ranged from 0.95 to 2.174%, while the commercial brake pad had a value of 1.031%. For the hardness tests, at three different loads, the developed values ranged from 16.4HV3 to 19.4 HV3; 26.4HV30 to 28.7HV30; and 25.5HV100 to 29.6HV100, while the commercial brake pad had values of 16.5HV3, 28.4HV30 and 28.2HV100.Sample C (212 μm: coconut shell powder) exhibited the most desirable characteristics with five values: water absorptivity 0.95, compressive strength 120.5 MPa, hardness value 29.6 HV100, wear resistance 0.099 mm/mm3, specific wear rate 1.00 mm3/Nm. The outstanding values were attributed to the chemical composition, particle sizes and good interfacial bonding of the microstructure.The developed brake pads performed favourably when compared with the existing commercial brake pads. The chemical tests showed that the natural fibres bonded well with the epoxy matrix. The thermal and mechanical tests yielded comparable results with the values obtained from the commercial brake pads. Therefore, the developed materials for brake pads can be considered suitable replacements for asbestos brake pads.
