A combination of dynamic shear rheology, thermomechanical analysis (TMA), scanning electron microscopy (SEM), Near-Edge X-ray Absorption Fine Structure (NEXAFS), and fracture toughness testing was utilized to characterize the thermal, mechanical, chemical, and fracture properties of alumina (alpha-Al2O3)-filled epoxy resins as a function of average filler size, size distribution, particle shape, loading, and epoxy crosslink density. In general the cured properties of the filled composites were robust. Small changes in particle size, shape, and size distribution had little impact on the final properties. Resin crosslink density and filler loading were the most critical variables, causing changes in all properties. However, most applications could likely tolerate small changes in these variables also. SEM and NEXAFS characterization of the fracture surfaces revealed that the fracture occurs at the filler interface and the interfacial epoxy composition is similar to the bulk resin, indicating a weak epoxy-alumina interaction. These results are critical for implementation of particulate-filled polymer composites in practical applications because relaxed material specifications and handling procedures can be incorporated in production environments to improve efficiency. (C) 2007 Elsevier Ltd. All rights reserved.