Plastic pollution is considered a key issue that creates several health and environmental problems. Consequently, recycled plastic emerges as a more environmentally friendly option, although its implementation requires significant financial and time commitments. Furthermore, a composition consisting of natural fiber extracted from date palm agro-residue and recycled plastic is utilized as a leading technology and approach to make new materials from waste. Currently, the majority of agro-residues are burned and sent to dumping sites. While this approach may offer a source of income and an environmental solution, the most common plant in Oman is the date palm, known for its unique strength and flexibility, which can be employed in bio nanocomposite manufacturing. This project aims to investigate the mechanical properties of 3D-printed bio nanocomposite crafted from date palm fiber and recycled polypropylene. Since the fibers enhance the elasticity of the bio nanocomposite and reduce its weight, the main mechanical criteria used were tensile, flexural strengths and water absorption tests, which will be compared with the ones obtained by traditional manufacturing methods. Subsequently, optimization will be pursued in the second stage of the project. The results indicate an improvement in the mechanical properties of recycled polypropylene (rPP) after applying natural Nano Date Palm Particles (NDPP). Additionally, adding fiber to polymers increases their ability to absorb water. Moreover, the second stage of the project involves filament production, starting with selecting the appropriate fiber measurement. A three percent fiber was selected since it yielded the best results compared to five and ten percents. This was followed by filament production using a single screw extruder machine for both recycled polypropylene and Nano Date Palm Particles. A Design of Experiment (DoE) is utilized to determine the experimental runs of 3D printing, followed by data analysis and optimization.