Open Access

REVIEW

Carbon-Based Polymer Composites and Nanocomposites: Innovations and Emerging Trends

Md Arifuzzaman^1,*, Mohammod Hafizur Rahman², Sayeed Rushd³, Mohammad Anwar Parvez³, Mohammad Rakib Hasan⁴, Md Enamul Hoque⁵

1 Department of Civil and Environmental Engineering, College of Engineering, King Faisal University, Al Ahsa, 31982, Saudi Arabia
2 Chemical Engineering Department, College of Engineering, Imam Mohammad Ibn Saud Islamic University (IMSIU), Riyadh, 11432, Saudi Arabia
3 Department of Chemical Engineering, College of Engineering, King Faisal University, Al Ahsa, 31982, Saudi Arabia
4 RAC Research and Innovation Department, Walton Hi-Tech Industries PLC., Gazipur, Bangladesh
5 Department of Mechanical Engineering, Faculty of Engineering, University of Tabuk, Tabuk, 71491, Saudi Arabia

* Corresponding Author: Md Arifuzzaman. Email:

Journal of Polymer Materials 2026, 43(3), 4 https://doi.org/10.32604/jpm.2026.089953

Received 28 July 2026; Accepted 17 September 2026; Issue published 24 September 2026

Abstract

Advanced multifunctional materials, Carbon-Based Polymer Composites (CBPCs) have attracted wide attention due to their excellent mechanical, thermal, electrical and barrier properties. Carbon-Based Reinforcements (CBRs) such as Carbon Nanotubes (CNTs), Graphene (GR), Graphene Oxide (GO) and biochar greatly improve the performance of polymer matrices while retaining lightness. The high strength to weight ratio, thermal stability, electrical conductivity and Electromagnetic Interference (EMI) shielding property of these composites have given rise to enormous interest in their use in aerospace, automotive, construction, electronics and biomedical applications. This review is grounded in 106 papers published from 2024 to 2026 and identified from Scopus, Web of Science, ScienceDirect, SpringerLink, Wiley, and IEEE Xplore databases following specific selection criteria. Different synthesis and fabrication methods, including hand lay-up, compression moulding, Resin Transfer Moulding (RTM), Additive Manufacturing (AM), electrospinning, melt blending, and in situ polymerisation, are critically examined. In addition, mechanical/thermal/barrier/electrical properties and their effects with the carbon fillers are examined in detail, and especially tensile strength, flexural behaviour, thermal conductivity, electrical conductivity, EMI shielding effectiveness and durability. Different carbon reinforcements are compared in terms of performance, sustainability, cost and scalability. Besides, the durability factors, environmental issues, Life Cycle Assessment (LCA) and new industrial applications are presented. Lastly, the problems existing in the field, research gaps, and prospects are identified and discussed with particular focus on sustainable carbon nanomaterials, green manufacturing processes and advanced multifunctional composites. There was an improvement in the composite performance in the reviewed studies. Composites with graphene and CNTs improved their mechanical, thermal, and electrical properties. Carbon fibre composites showed improvement in mechanical and stiffness properties, while biochar composites showed 15–40% improvement in mechanical properties and were more economical and sustainable. Reported performance improvements were interpreted according to the polymer matrix, filler type and loading, processing conditions, and testing methods, ensuring accurate and comparable quantitative claims across the reviewed studies.

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Keywords

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