Sandwich composites were fabricated successfully with the balsa wood as core material and regenerated cellulose fabric bio-based polypropylene (PP) composite skins. The regenerated cellulose fabric PP composites were produced using two different methods: the conventional stacking lay-up and directly using PP pellets. Sandwich composites were made using the hot press equipment with the customized mold. The sandwich composite system and bio-composite laminate were designed to achieve very close weight to compare the key mechanical properties that each design can bear. It was evidenced from the experimental results that 416% increase in the bending load bearing property of the part can be obtained when sandwich structure was used. These experimental results were in close agreement with one of the analytical modelling utilised. The drop weight impact test results demonstrated that the sandwich specimen is capable of withstanding more than 6 kN load and absorbing the impact energy of 28.37 J.