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The increasing demand for renewable energy and the environmental impact of agricultural residue burning have intensified interest in the production of bio-briquettes from agro-wastes. This study investigated the production and characterization of bio-briquettes from maize (corn) husk using cassava starch, paper pulp, and clay binders at varying particle sizes (70 % and 35 % mesh) and binder concentrations (15 % and 30 %). The briquettes were evaluated for density, shatter index, moisture content, porosity, ash content, volatile matter, fixed carbon, mechanical strength, and calorific value. Results indicated that binder type, concentration, and particle size significantly influenced briquette properties. Briquettes produced with 30 % cassava starch binder exhibited moderate density (0.03–1.05 g/cm³), high fixed carbon (58.67 %), low moisture content (8.2 %), low ash content (3.5 %), and the highest calorific value (16.2 MJ/kg). Paper-only briquettes displayed higher shatter index (97.27 %) and moderate moisture content, while mixed binders increased moisture and volatile matter but enhanced mechanical stability. Clay-bound briquettes exhibited the poorest performance, with low density (0.80 g/cm³), high ash content (8.9 %), and reduced calorific value (13.6 MJ/kg). These findings demonstrate that maize husk can be efficiently converted into solid biofuel with suitable mechanical and combustion characteristics. The study highlights the critical role of binder selection in optimizing energy efficiency, structural integrity, and overall briquette quality, offering a sustainable renewable energy alternative for domestic and industrial applications.