ABSTRACTThe potential of preformed elastomers as a toughening agent for epoxy–glass syntactic foam has been explored. Poly(dimethylsiloxane) microspheres were prepared by suspension polymerization. The microsphere dimensions could be varied from 58 to 255 µm by tuning the reaction parameters, particularly the stirring speed and feed concentration. Rheological studies indicated that the introduction of microballoons led to an increase in the viscosity of the resin, with the extent being proportional to the microballoon content. The zero shear viscosity increased from ∼103 mPa s at 30 °C to 105 mPa s as the microballoon loading was increased to 40%. Syntactic foams containing varying amounts of microballoons (40–60% v/v) were prepared, and an analogous set of toughened foams were also prepared, where a fraction of the microballoons was replaced with poly(dimethylsiloxane) microspheres (3–7%). The effect of increasing dimensions of the elastomeric microspheres on the mechanical properties was also studied. The improvement in properties was more pronounced when the microsphere size was equivalent to that of the constituent microballoons. An improvement of 40% and 185% in flexural strength and flexural toughness was observed upon the introduction of poly(dimethylsiloxane) microspheres of optimal dimensions (diameter ∼63 µm, 5% loading), without any undesirable increase in foam density. However, the compressive properties remained practically unaltered. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018, 135, 45882.