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The technique for synthesis of poly (methyl methacrylate) (PMMA) by atom transfer radical polymerization has been strengthened by using graphene nanoplatelets (GNPs) to enhance the elastic properties of the polymer. In order to improve practical, economical and mechanical performance, the requirements for effective implementation of production control as a smart bulk polymer nanocomposite were determined for cost-effective bulk production. Threedimensional inspection (using an ultrasound interrogation method for the whole volume under test) confirmed the synthesis of the nanocomposite to be free of agglomeration and bubbles. As a result of this elimination of defects, an enhancement in compressive strength of 42.7% was achieved and the Rockwell hardness was increased by 19.9% through the addition of GNPs at 2 wt% by mass. The deformation and mechanical failure properties have been characterized in the mechanical enhancement of the polymer nanocomposite. Elastic parameters determined using ultrasound testing identified that changes in the structural features following the addition of these GNPs were uniquely connected to the enhancements in these elastic parameters (such as Young's modulus, Poisson's ratio, shear modulus, and microhardness) of the PMMA/GNPs nanocomposite.

The graphene nanofiller (2 wt%) was dispersed in poly(methyl methacrylate) by in situ polymerization method. The optimum high frequency (microwave) absorption was evaluated at X‐band due to changes in the scattering parameters (determined by using a vector network analyzer). The slight improvement has been attained in gamma attenuation coefficient of the polymer nanocomposite by using gamma transmission technique. The addition of graphene nanoplatelets (2 wt%) resulted in a thermal improvement from 196.73 to 243.00°C (with 5% weight loss) in TGA analysis. The graphene nanoplatelets provided an optimum decrease in scattering of the microwaves due to the elimination of the defects and the prevention of the agglomeration of the graphene nanoplates. The improvement of microwave absorption (between 8 and 12 GHz) suggested that the nanocomposite was a suitable candidate as a microwave absorbing material. This multipurpose nanocomposite has provided thermal stability and it has ensured the optimum gamma‐ray and microwave absorption depending on the development of the structural properties. The development of these physical characteristics has enabled to improve the electrical conductivity as a result of the progress in the structural properties.

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The modification of PMMA materials was provided by the application of a suitable degass process to obtain the porous structure. The application of a suitable degass process has enhanced the affordable weight reduction. The gamma transmission technique was used in order to examine the details on high precision processing and fabrication of the modified PMMA polymer as the affordable weight reduction of PMMA polymer supported for their use in high-volume vehicles and components.

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