<p>The study focuses on developing and processing of bio-degradable coconut and rice husk natural fiber-reinforced epoxy resin (LY 556) polymer composites. Study explored the hand lay-up technique for fabrication of the composite. The physical and mechanical characteristics of the fabricated composites were assessed using standardized testing methods. Additionally, processing of the composite through hybrid machining on a designed and developed Travel Wire Electrochemical Discharge Machining (TWECDM) setup. The machining performance was evaluated based on material removal rate (MRR, mg/min) and spark gap width (Wg, µm). Analysis of variance (ANOVA) indicated that DC supply voltage (DCSV) was the predominant factor influencing MRR with 69.3 F-test value and 67.22% contribution at 95% confidence level. The parameter DCSV also identified as the most significant parameter for Wg with 86.13 F-test value and 65.76% contribution at 95% confidence level. Optimal combinations of TWECDM parameterswere identifiedfor higher MRR (mg/min) and for lower Wg (µm) and explained in the manuscript. Mathematical models were created to forecast MRR and Wg across different parametric conditions, serving as a valuable resource for pre-experimental planning. Initial micro-slicing observations indicated somewhat greater widths and poor surface quality, owing to undissolved coconut fibers and rice husks, underscoring the necessity of strategic machining operations. The research finds that the hand lay-up approach and hybrid TWECDM process are efficacious for the fabrication and machining of coconut and rice husk-based natural fiber bio-degradable composites, with the established models and optimized parameters providing significant guidance for efficient processing.</p> Graphical abstract <p></p>