The current study examines the effects of varying the amount of coal ash (CA) used as a filler in woven aramid epoxy (AE) reinforced composites from 0% to 12% by weight. This includes testing the composites’ mechanical, water absorption, and thermal characteristics. Samples were made using a hand lay up approach, and then their qualities are evaluated using conventional ASTM procedures. Industrial fly ash is produced when pulverized coal is burned in a thermal power station. It is a metal oxide combination that is a contaminant that must be disposed of or used. Therefore, turning an industrial byproduct like CA into a bio-reinforced composite material would be a win-win situation. The tensile strength, flexural strength, inter-laminar shear strength (ILSS), and microhardness of the AE composites are all found to increase when 6 wt.% filler is added. The flexural strength decreases by around 20% and the tensile strength by about 7.5% when compared to non-filler loaded composites when filler is added at a weight of 12 wt.%. Microhardness is decreased by 17.4%, and ILSS is decreased to 19.5%. CA filler has a negative effect on impact strength. CA filler added to aramid fiber decreases the composites’ heat conductivity and water absorption.

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