Abstract <p>In the era of technologically driven world, the increasing cost of conventional composite materials, low-biodegradability of plastic wastes and huge generation of fruit wastes are the causes of worriment. The pursuit of eco-friendly and biodegradable products has fueled the research for the development of eco-friendly materials. Banana peel powder (BPP) can be a promising biofillers for the enhancement of performance of polymeric composites. Polylactic acid (PLA) is a biodegradable polymer which possess a little or no detrimental effect to the environment after their disposal.&#xa0;The research was sought to develop a novel and sustainable biocomposite by utilizing BPP and PLA for structural applications such as; bumpers of automobiles, internal door structures and window panels where the concern for the mechanical performances is of prime importance. The biocomposite samples were developed by using BPP in different loading fractions such as 5, 10, 15 and 20 (wt.%) and PLA through additive manufacturing technique. The effect of biofillers as BPP reinforcements on mechanical properties was investigated. The optimum compressive strength and tensile strength were obtained to be 70.16&#xa0;MPa and 44.40&#xa0;MPa, respectively. The compressive strength and tensile strength were found to improve by 28% and 19% respectively, in comparison with the neat PLA sample. The maximum impact strength was found to 20,000&#xa0;kJ/m² for the composite B20P80. The study has revealed that the incorporation of biofillers in suitable fractions can significantly improve the mechanical performances of the polymeric composites. The developed biocomposites is potent to replace the conventional composites and promotes circular economy in modern industries.</p> Graphical Abstract <p></p>