the present invention relates to a process for the manufacture of structural hybrid thermoplastic composites where organic and inorganic fibres are well dispersed in a thermoplastic matrix . the process comprises defibrillating the organic fibres with or without the presence of surface active agents using a mixer at a high shear and at a temperature lower than the decomposition temperature of organic fibres and melting point of the surface active agents to separate the hydrogen bonded fibres and generate microfibres , followed by blending and dispersion of the organic fibres in the thermoplastic matrix to produce a fibre composite , followed by further blending and dispersion of the fibre composite with inorganic fibres at a low shear to get the moldable hybrid composite , followed by extrusion , injection or compression - injection molding . low shear mixing maintains the inorganic fibre length . the process produces high performance composite materials having excellent performance properties and are ideally suited for automotive , aerospace , furniture , sports articles , upholstery and other structural and semi - structural applications .