The continuously increasing volume of waste tires poses potential environmental hazards; consequently, tire powder is utilized as a reinforcing material for epoxy-matrix composites. This study aims to investigate the effect of varying tire powder volume fractions (Vf) on the mechanical properties of the composites—specifically tensile strength, impact toughness, and hardness. Specimens were fabricated using a casting method with volume fractions of 20%, 40%, and 60%, and tested in accordance with ASTM standards D638, D256, and D2240. The highest tensile strength and modulus of elasticity were observed at a Vf of 20% (15.67 MPa; 21.89×10⁻³ GPa) and decreased as the Vf increased to 60% (4.9 MPa; 4.28×10⁻⁴ GPa), whereas strain increased from 7.09% to 26.78%. Fracture energy and impact toughness increased with higher Vf, rising from 5.26 J and 0.04 J/m² to 8.5 J and 0.06 J/m², respectively. Hardness exhibited a non linear pattern: the highest value was recorded at a Vf of 20% (75.33 Shore A), decreased at 40% (70.66 Shore A), and increased again at 60% (74 Shore A). Given that no single Vf value is optimal for all mechanical properties, the selection of the volume fraction should be tailored to the specific loading requirements of the intended application.
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