Polymer Nanocomposites at the Nanoscale: A Comprehensive Review with Reference to Indian Regulations

Abstract

By combining nanoscale reinforcements with polymer matrices, polymer nanocomposites have become one of the most promising classes of advanced materials with superior mechanical, thermal, electrical, barrier and multifunctional properties. This extensive review critically analyses the scientific advances made in polymer nanocomposites between 2000 and 2026, with focus on recent advances in polymer nanocomposite development, processing techniques, structure–property relationships and new applications. The review covers the impact of the nanofillers which are widely researched – such as carbon nanotubes, graphene and its derivatives, nanoclay, metal or metal oxide nanoparticles, nanocellulose, MXenes, and other modern nanofillers – on the improvement of polymer matrices properties. In addition, important fabrication methods – like solution blending, melt compounding, in situ polymerization, electrospinning, and additive manufacturing – are discussed, with a particular focus on the dispersion of the nanoparticles, the engineering of interfaces, and the scalability of fabrication. The recent advances up to 2026 on the multifunctional polymer nanocomposites, such as self-healing, biodegradable, flame resistant, electrically conductive, shape memory, and smart sensing, are all broadly discussed in various applications including aerospace, automotive, biomedical engineering, flexible electronics, energy storage, packaging and environmental remediation. Also highlighted in the review are key issues of nanoparticle agglomeration, recyclability, environmental sustainability, toxicity, commercialization, and regulatory aspects. This review summarizes the most recent scientific advances in the field and points the way forward in research, giving an updated reference for researchers, engineers and industrial practitioners in the field of next generation high-performance polymer nanocomposites.