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This investigation adopts composite methodology by reinforcing ZK61 with hydroxyapatite (HA) and eggshell (ES) to fabricate Mg-based metal matrix composite using friction stir processing (FSP). The impact of introducing 10\u2009wt% HA as a bioactive ceramic and 2.5\u2009wt% ES as a green, low-cost reinforcement via FSP on mechanical performance, in vitro corrosion behaviour, and biocompatibility is reported. The microhardness and ultimate compressive strength of the ZK61-10HA-2.5ES composite (74.6\u2009HV, 356\u2009MPa) showed a \u223c24% increase in microhardness and a \u223c28% increase in UCS compared to ZK61 alloy (60.1\u2009HV, 278\u2009MPa). The corrosion rate of ZK61-10HA-2.5ES composite was assessed using electrochemical measurements and found a lower corrosion rate (1.05\u2009mm\/year) compared to ZK61 alloy (3.63\u2009mm\/year), which aligned with the results obtained from immersion. After 1 and 3\u2009days of incubation, the MTT assay revealed that the ZK61-10HA-2.5ES composite exhibited grade 0 non-cytotoxic response to MG-63 cells, indicating its promising potential for orthopaedic applications.<\/jats:p>","DOI":"10.1177\/09544119261463379","type":"journal-article","created":{"date-parts":[[2026,7,20]],"date-time":"2026-07-20T04:30:30Z","timestamp":1784521830000},"page":"768-781","update-policy":"https:\/\/doi.org\/10.1177\/sage-journals-update-policy","source":"Crossref","is-referenced-by-count":1,"title":["Investigation on mechanical, in vitro corrosion, and biocompatibility behaviour of ZK61-10HA-2.5ES hybrid bio-composite for orthopaedic implant applications"],"prefix":"10.1177","volume":"240","author":[{"ORCID":"https:\/\/orcid.org\/0009-0006-6244-5824","authenticated-orcid":false,"given":"Harshit","family":"Kumar","sequence":"first","affiliation":[{"name":"Production and Industrial Engineering Department, National Institute of Technology Jamshedpur, 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