A quantitative processing–structure–property framework for selecting fabrication routes in high-performance thermoplastic nanocomposites

Selecting an appropriate fabrication route for high-performance thermoplastic nanocomposites remains a significant engineering challenge because existing studies primarily evaluate individual processing techniques without providing a unified quantitative framework for objectively comparing their effects on microstructure, multifunctional properties, and manufacturing scalability. Unlike conventional comparative studies that evaluate fabrication techniques independently, this work develops a unified quantitative processing–structure–property framework that establishes objective relationships between fabrication route, nanofiller dispersion, network formation, multifunctional performance, and manufacturing readiness using a common polypropylene/carbon nanofiller system under consistent processing conditions. Melt compounding, solution blending, and electrospinning were systematically evaluated through morphological, mechanical, thermal, and electrical characterization. Electrospinning achieved the highest dispersion quality (dispersion index: 0.88; agglomerate size: ∼1.2 μm), resulting in approximately 60% tensile modulus enhancement and electrical conductivity approaching 10° S·m −1 . Melt compounding provided a balanced combination of mechanical performance (approximately 45% modulus improvement), industrial scalability, and processing efficiency, whereas solution blending exhibited intermediate performance but was limited by nanofiller re-agglomeration during solvent evaporation. Thermal stability improved by up to 30°C in onset degradation temperature, accompanied by increased residual char yield. Based on these quantitative results, a processing-selection framework and comparative performance map were developed to relate fabrication route, dispersion quality, network continuity, multifunctional performance, and manufacturing readiness. The proposed framework provides transferable engineering guidelines for selecting fabrication strategies according to application-specific performance requirements and industrial constraints, offering a practical decision-making tool for the rational design and scalable manufacturing of next-generation thermoplastic nanocomposites.