The processing and characterization of hybrid PMMA resin composites with nano-zirconia (ZrO2) and electrospun polystyrene (PS) polymer fibers were presented in this study. Reinforcement was selected with the intention to tune the physical and mechanical properties of the hybrid composite. Surface modification of inorganic particles was performed in order to improve the adhesion of reinforcement to the matrix. Fourier transform infrared spectroscopy (FTIR) provided successful modification of zirconia nanoparticles with 3-Methacryloxypropyltrimethoxysilane (MEMO) and bonding improvement between incompatible inorganic nanoparticles and PMMA matrix. Considerable deagglomeration of nanoparticles in the matrix occurred after the modification has been revealed by scanning electron microscopy (SEM). Microhardness increased with the concentration of modified nanoparticles, while the fibers were the modifier that lowers hardness and promotes toughness of hybrid composites. Impact test displayed increased absorbed energy after the PS electrospun fibers had been embedded. The optimized composition of the hybrid was determined and a good balance of thermal and mechanical properties was achieved.

To obtain flakes like zirconia particles at relatively low temperature, the synthesis method for producing zirconia particles on the surface of salt particles that serve as a template is examined. The produced particles are incorporated as reinforcement in the poly(methyl methacrylate) matrix to obtain a composite material. The particles were characterized by the X-ray diffraction, Fourier-transform infrared spectroscopy, and image analysis. The morphology of the particles and composites was examined using a field emission scanning electron microscope. Composites prepared with synthesized particles were compared to those containing commercial zirconia particles to estimate the possibility of use of synthesized particles as reinforcement. The influence of the 1 wt% of zirconia particles in composite material on the mechanical properties was studied using microhardness measurements and dynamic mechanical analysis. The results obtained show that the addition of 1 wt% of zirconia particles increases the mechanical properties of the composite relative to the pure polymer matrix.