A highly filled PVA/talc composite was prepared through our invented thermal processing technology without using any coupling agent or compatibiliser. The results showed that compared with neat PVA, the melt temperature of the composite decreased and the degradation temperature increased, providing a big temperature window for thermal processing of PVA/talc composite. The composite melt exhibited shear thinning behaviour while its viscosity increased with increasing talc, still satisfied the requirement of thermal processing. The morphology analysis confirmed that talc was well dispersed in PVA, improving heat deflection temperature (HDT), tensile strength and modulus of PVA. When talc was 50 wt-%, the HDT, tensile strength and modulus of the composite were 115uC, 48 MPa, 1?23 GPa respectively, increased by 92, 16 and 150%, compared with PVA, and the elongation at break was 100% of the composite, confirming that the high filled PVA/talc composite was a novel PVA based material with excellent thermal and mechanical properties.