Within this paper, we are dealing with a mixture of thermoplastic polymer that is filled with inorganic fillers at high concentrations up to 60 vol.%. A high number of particles in the compound can substantially change the rheological behaviour of the composite and can lead to problems during processing in the molten state. The rheological behaviour of highly filled materials is complex and influenced by many interrelated factors. In the present investigation, we considered four different spherical materials: steel, aluminium alloy, titanium alloy and glass. Particles with similar particle size distribution were mixed with a binder system at different filling grades (30–60 vol.%). We showed that the rheological behaviour of highly filled materials is significantly dependent on the chemical interactions between the filler and matrix material. Moreover, it was shown that the changes of the particle shape and size during processing lead to unexpected rheological behaviour of composite materials as it was observed in the composites filled with glass beads that broke at high contents during processing.

The focus of this paper is the realization and verification of a modified fiber bundle pull-out test setup to estimate the adhesion properties between threads and elastic matrix materials with a more realistic failure mode than single fiber debond techniques. This testing device including a modified specimen holder provides the basis for an adequate estimation of the interlaminar adhesion of fiber bundles including the opportunity of a faster, easier, and more economic handling compared to single fiber tests. The verification was done with the single-fiber and microbond test. Overall, the modified test setup showed the typical pull-out behavior, and the relative comparability between different test scales is given.

The interface between the reinforcement and surrounding matrix in a fibrous composite is decisive and critical for maintaining component performance, durability, and mechanical structure properties for load coupling assessment, especially for highly flexible composite materials. The clear trend towards tailored solutions reveals that an in-depth knowledge on surface treating methods to enhance the fiber–matrix interfacial interaction and adhesion properties for an optimized load transfer needs to be ensured. This research aims to quantify the effect of several surface treatments for glass fibers applied in endless fiber-reinforced elastomers with pronounced high deformations. Due to this, the glass fiber surface is directly modified with selected sizings, using a wet chemical treatment, and characterized according to chemical and mechanical aspects. For this purpose, the interfacial adhesion performance between fibers and the surrounding matrix material is investigated by a modified fiber pull-out device. The results clearly show that an optimized surface treatment improves the interface strength and chemical bonding significantly. The fiber pull-out test confirms that an optimized fiber–matrix interface can be enhanced up to 85% compared to standard surface modifications, which distinctly provides the basis of enhanced performances on the component level. These findings were validated by chemical analysis methods and corresponding optical damage analysis.