In order to save material and energy, an increased growth can be noticed in recent times in the use of low-cost and light-weight solutions for the interior dividing walls of buildings. In this context, the main aim of the present research work was to develop light-weight composite panels based on non-woven fabrics for this application as an alternative to more commonly used materials and to optimize the manufacturing process parameters in order to maximize their mechanical performance. Thermo-bonded nonwoven geo-textiles made from polyester (70%) and polypropylene (30%) fibres were consolidated using compression moulding technique, varying the various structural and process parameters, such as number of layers, compression time, temperature and pressure. Taguchi method was used to design the experiments, as well as to understand the influence of various parameters on tensile and flexural strengths of developed composite panels and to optimize them in order to maximize these properties. According to the analysis, a consolidation temperature of 210°C, pressure of 30 bars, compression time of 35 minutes and 30 layers are required to achieve the maximum values of tensile and flexural strength with minimum variability.