Structure–Property Relationships of Hot-Pressed Wood–Polymer Composite Boards from Recycled ABS Edge-Banding Waste and Wood Fibers

Recycled thermoplastics offer a promising route for valorizing industrial residues and developing thermoplastic-bonded wood-based panels without added formaldehyde-based resins. In this study, experimental wood–polymer composite boards were produced from recycled acrylonitrile–butadiene–styrene (ABS) edge-banding waste used as the polymer matrix and industrial wood fibers used as the lignocellulosic reinforcement. The boards were manufactured at target densities of 800–1200 kg·m−3 and wood fiber contents of 10–30%, followed by the evaluation of selected physical and mechanical properties, including water absorption, thickness swelling, modulus of elasticity and bending strength. Thermogravimetric analysis of the recycled ABS edge-banding material and qualitative optical microscopy of the board surfaces were used to support, but not independently prove, the interpretation of the composite structure. The recycled ABS waste enabled the formation of compact boards, with density exerting the strongest influence on water resistance and bending performance. The regression models indicated a balanced region at 21.84 wt.% wood fibers and 1134 kg·m−3, corresponding to predicted water absorption of 1.62%, thickness swelling of 3.22%, modulus of elasticity of 2931 N·mm−2 and bending strength of 22.20 N·mm−2. Optical microscopy suggested a more continuous ABS-rich surface in the most homogeneous specimens, whereas local accumulations of fine particles and areas of limited polymer coverage were observed on the opposite surface. These findings demonstrate the potential of recycled ABS edge-banding waste for wood–polymer board production, while indicating that additional feedstock cleaning and sieving should be investigated in subsequent work to improve furnish uniformity and structural homogeneity.