Engineering high-performance EPDM nanocomposites: Effects of nanofiller type, loading, and dimensionality

This review provides a comprehensive synthesis of recent developments in ethylene propylene diene monomer (EPDM) nanocomposites, emphasizing how interfacial engineering, dispersion strategies, and optimized nanofiller loading govern performance enhancement. Nanofillers are evaluated according to their dimensionality—0D, 1D, 2D, and hybrid systems—to elucidate how typical concentrations (1–10 wt%) influence dispersion quality, network formation, and percolation behaviour. These factors directly impact mechanical reinforcement, thermal stability, electrical properties, and dielectric reliability. Key trends indicate that excessive nanofiller loadings increase viscosity and promote agglomeration, thereby limiting processability, while optimized concentrations enable substantial property improvements. Representative advances include significant increases in tensile strength, enhanced thermal decomposition temperatures, and improved dielectric breakdown performance using hybrid filler networks. Strategies to address compatibility challenges—such as surface functionalization and advanced dispersion techniques, including ultrasonic processing—are discussed as essential to achieving uniform filler distribution. Despite rapid progress, unified guidelines for nanofiller selection, dimensionality, and concentration remain underdeveloped. This review identifies these gaps and proposes design principles and research directions for sustainable, multifunctional EPDM nanocomposites. The insights provided support future advancements in high-performance applications, including high-voltage insulation, sealing systems, automotive components, neutron shielding, and emerging energy and electronic technologies.