Consumer preference for high-fibre plant-based meat substitutes is growing due to health concerns, environmental sustainability and affordability. However, little is known about the use of locally sourced ingredients like wasted cashew-apple fibre and underutilized Bambara beans in the preparation of plant-based sausages that satisfy consumers’ demand. The study aimed to develop and standardize a plant-based sausage by combining cashew apple fiber, a by-product of cashew apple processing, with Bambara beans, a protein-rich, drought-resistant legume. Four sausage formulations with cashew-apple fibre (C) and Bambara beans (B) as main ingredients (CB1:0, CB1:1, CB2:1 and CB4:3) were developed using an extreme vertices design via Minitab 2.1. Each of the sausage formulations was filled into a cellulose film casing, steamed for 20 mins, cooled, vacuum packaged and frozen at -18 ^oC for analysis. The samples were assessed for nutritional, microbiological, physical, and sensorial qualities. The results showed that, protein increased from 2.02% to 15.41% and carbohydrate reduced from 22.63% to 9.93% as the percentage of Bambara in the formulation increased. Vitamin C ranged from 9.43–11.29 mg/100 g, and mineral content covered 9–26% of the recommended dietary intake for calcium, phosphorus, and iron. Total plate count, Enterobacteriaceae, E.coli, Staphylococcus aureus, Bacillus cereus, and Salmonella were not detected in the samples. It was also found that Bambara beans improved hardness, cohesiveness, and resilience of the sausages while fiber content was improved with increasing cashew apple fibre ranging from 0.51 to 2.48 mg/100g. Sensory testing with 16 semi-trained panelists identified CB2:1 and CB4:3 as the most liked. Consumer testing with 104 untrained panelists further confirmed broad acceptance across demographic groups. The findings demonstrate that cashew apple fiber and Bambara bean can be successfully combined to produce a nutritious, safe, and consumer-acceptable plant-based sausage.