This work reports the preparation of polycarbonate-silica nanocomposite by simple one-step injection moulding process. Silica nanopowder was first functionalized with a silane coupling agent, (3-methacryloxypropyl)trimethoxysilane (MPS). Polycarbonate pellets mixed with 5 wt% functionalized-silica nanopowders were then compounded by using a Brabender counter-rotating twin screw compounder followed by subsequent injection molding process. The distribution of silica was examined using transmission electron microscopy (TEM). The FT-IR spectra were used to investigate the MPS-modified SiO2 nanopowders. The thermal properties of the nanocomposite were studied by differential scanning calorimeter (DSC). Pencil hardness is increased from B to HB with the incorporation of 5 wt% silica nanopowder. (C) 2010 The Society of Powder Technology Japan. Published by Elsevier B.V. and The Society of Powder Technology Japan. All rights reserved.