Polymer nanocomposites (PNCs) are a versatile class of materials known for their enhanced mechanical, thermal, electrical, and barrier properties, with the latter referring to resistance against the permeation of gases and liquids. Achieving optimal nanoparticle dispersion within the polymer matrix is essential to fully realizing these advantages. This study investigates strategies for improving nanoparticle dispersion and examines the impact of controlled dispersion on the resulting nanocomposite properties. Various methods, including in situ polymerization, twin screw extrusion, sol–gel processes, nanoparticle surface modification, solution casting, and advanced compounding techniques such as additive manufacturing and self-healing composites were explored to enhance dispersion and improve the compatibility between nanoparticles and polymers. The synergy between improved dispersion and enhanced functionalities—such as increased mechanical strength, thermal stability, conductivity, and chemical resistance—makes these nanocomposites highly valuable for industrial applications in sectors such as the automotive, aerospace, electronics, pharmaceuticals, and packaging industries. The key recommendations based on our findings highlight how customized nanocomposites can address specific industrial challenges, fostering innovation in materials science and engineering.

Bone regeneration is of great importance worldwide, because of various bone diseases, such as infections, tumors, and resultant fracture, birth defects, and bone loss due to trauma, explosion, or accident. Bone regeneration can be achieved by several materials and templates manufactured through various fabrication techniques. Uses of different materials and scaffold fabrication techniques have been explored over the past 20 years. In this research, polyetheretherketone (PEEK) was used to fabricate highly porous bionanocomposite foams for bone scaffolding. Melt casting and salt porogen (200–500 µm size) leaching methods were adapted to create an adequate pore size and the necessary percent of porosity, because pore size plays a vital role in cell implantation and growth. Porosity (75% and 85%) of the prepared scaffolds was adjusted by changing salt concentrations in the PEEK powder. Hydroxyapatite (HA) and carbon particles were used to improve cell attachments and interactions with the porous PEEK and to increase the mechanical properties of the scaffold materials. Carbon fiber (CF) and carbon nanotubes (CNTs) were uniformly dispersed into the PEEK powder before melt casting to enhance the mechanical properties and to observe the influence of the carbon particles on the properties of PEEK bionanocomposite foam. Compression test results of the fabricated bionanocomposites showed that HA and carbon particles are the potential filler materials for the enhancement of bionanocomposite mechanical properties. About 186% enhancement of compression modulus and 43% enhancement of yield strength were observed while incorporating only 0.5 wt% of CNTs into PEEK/HA bionanocomposites having 75% porosity, compared to PEEK/HA 20 wt% bionanocomposites. Micro-computed tomography (micro-CT) test results reveal that pore size and interconnectivity of the nanocomposite foams are in order and within the designed sizes. Mechanical tests proved that PEEK bionanocomposite foam has the potential for use in bone scaffolding and other biomedical applications.

To address the worldwide issue of water scarcity, which is threatening our sustainable economic development and ecological security, an efficient water-collecting surface with fast-capturing capability and easy drainage is essential.

A polymer matrix system of thermoset fiber-reinforced composites helps protect its high modulus and strength fibers from an adverse environment and transfers the load to the reinforced fibers. However, when subjected to a high temperature that exceeds its postcuring-stage temperature, the polymeric matrix will decompose or be charred. To address this issue, various techniques have been developed to improve the flame-retardant property of the polymeric matrix. One of these techniques is to either delay ignition or release moisture to extinguish the flame by combining other chemicals or reactively modifying the epoxy resin. Graphene oxide (GO) nanofilms deposited on top of composite surfaces were compared with the test results of nanocomposite coatings of GO and nanoclay particles on composite surfaces. GO thin film applied to the surface of fiber-reinforced composites acts as a heat shield to quickly dissipate heat and eliminate local heat formation. Thermal tests, such as thermogravimetric analysis (TGA), 45-deg burn tests, vertical burn tests, and surface paint adhesion tests were accomplished. Average burn lengths and the average burn areas were reduced with nanoparticle inclusion to the nanoclay samples and graphene samples. TGA analysis indicated that the nanoclay inclusion samples, as well as the graphene inclusion samples, have a higher percentage weight loss than that of the base sample. GO inclusion samples were less affected than nanoclay inclusion samples during the vertical as well as 45-deg burn tests. In addition, there were no signs of damage to the GO thin film that was secondarily bonded to the surface of composite panels for the burn test.