DGEBA-based epoxy nanocomposites filled with various amounts of fumed silica nanopowders (10, 20 and 30 phr corresponding to 3.3, 6.4 and 9.2% by volume) were prepared by a solvent assisted dispersion procedure. The obtained nanocomposites were analyzed by means of differential scanning calorimetry, dynamic-mechanical thermal analysis, uniaxial tensile tests on un-notched samples and three-point bending tests on notched samples. All the thermal and mechanical properties showed non-monotonic trends with relative minima as the silica content increased. A trend inversion in the physical properties was detected at the highest filler level tested, which was not previously observed for epoxy systems filled with comparable amounts of unmodified silica. The behavior could be explained by considering a reduction of cross-linking degree of the epoxy matrix due to the huge viscosity increase induced by the silica nanoparticles during composites preparation. On the other hand, the physical immobilization of the cross-linked matrix can be supposed to be responsible for the inversion of the properties trend at the highest filler level, which is presumably very close to the percolation threshold. (c) 2005 Elsevier Ltd. All rights reserved.