In the present paper an experimental investigation on natural palm fibers was carried out. The behavior of the natural fibers was extracted through tensile tests and thermal gravimetric analysis (TGA) test. A thermoplastic matrix of polystyrene (PS) and palm natural fibers was successfully gathering to form a sandwich composite with different fibers ratios. A thermoforming process was conducted to form the composite sheets with controlling production parameters such as speed, time and temperature. Based to the experimental results and measurements, the effects of forming process parameters and the fibers weight fractions for 0/90 degrees fibers orientations have a great impact on the composite behavior and influence the appearance of cracks, delamination and buckling in the final product surface. It was concluded that the composite Palm fibers (PF)/Polystyrene (PS) could be thermoformed and can be taken as replacement of several synthesis preformed composites in several industrial applications to achieve an efficient sustainable and waste management practice.