Interphase-Centric and Mechanism-Driven Advances in Polymer Composites Reinforced with Nano-, Synthetic, and Inorganic Fillers

Polymer composites reinforced with nanofillers, synthetic fibers, and inorganic fillers have progressed rapidly, yet recent advances remain fragmented across filler-specific studies and often lack unified mechanistic interpretation. This review addresses this gap by presenting an interphase-centric, mechanism-driven framework linking processing routes, dispersion and functionalization requirements, interphase formation, and the resulting structure-property relationships. Representative quantitative datasets and mechanistic schematics are integrated to rationalize nonlinear mechanical reinforcement, percolation-controlled electrical/thermal transport, and thermal stabilization and barrier effects across major filler families. The review highlights how reinforcement efficiency is governed primarily by interfacial adhesion, filler connectivity, and processing-induced microstructural evolution rather than filler loading alone. Key challenges limiting scalability are critically discussed, including dispersion reproducibility, viscosity and processability constraints, interphase durability, and recycling compatibility. Finally, mechanism-based design rules and future outlook directions are provided to guide the development of high-performance, multifunctional, and sustainability-oriented polymer composite systems.