In this article, we report the effect of various carbon nanoparticle concentrations on the structural, curing, tan δ, viscosity variation during vulcanization, thermal, and mechanical characteristics of ethylene–propylene–diene monomer polymer sponge composites. The purpose of this study was to develop high-strength, foamy-structure polymer composites with an optimum filler to matrix ratio for advanced engineering applications. We observed that the structural, vulcanization, viscoelastic, and mechanical properties of the fabricated composites were efficiently influenced with the progressive addition of carbon content in the rubber matrix. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014, 131, 39423.