Upcycling Agave cantala leaf waste into biocomposite leather-like material via structural design and fibre reinforcement.

This study presents a bio-based leather-like composite developed from Agave cantala leaf waste, valorizing the succulent fraction that constitutes nearly 70% of leaf biomass discarded during decortication. Through oxidative alkaline modification and mechanical exfoliation, the native technical fibre bundles are transformed into a hierarchical network of flexible cellulose micro ribbons, while the amorphous parenchymatous phase forms a porous cellular morphology. Together, these phases form a synergistic fibre-reinforced matrix system that provides a leather-like structure at the micro level, without implying molecular or biochemical replication of animal collagen. When integrated with a biodegradable polymer binder and cotton twill backing, the resulting composite exhibited a tensile strength of 8.51 ± 0.17 MPa and tear resistance of 30.37 ± 0.87 N mm-1, outperforming established commercial plant-based leathers such as Desserto® and Piñatex® in tear resistance. Fourier Transform Infrared Spectroscopy (FTIR) analysis and thermogravimetry analysis (TGA) confirmed selective delignification, cellulose enrichment, and the formation of thermally stable condensed structures supporting interfacial interaction and char formation. By utilizing agricultural by-products, this approach offers a sustainable alternative to conventional leather production while avoiding chrome-based tanning processes and reducing the environmental burden associated with biomass waste. Although a detailed life cycle assessment is beyond the scope of this study, the results demonstrate a scalable pathway for upcycling Agave cantala leaf waste into a bio-based leather-like composite with competitive mechanical performance for selected flexible sheet applications.