We describe a novel approach for manufacturing polymer composites using friction predicated processes such as friction extrusion, friction processing, and shear assisted processing and extrusion (ShAPETM) technology. Existing techniques for manufacturing polymer composites, specifically thermoplastic based materials, are unable to incorporate high volume/weight fraction of additives beyond 60 wt.% uniformly in the composite microstructure. However, there is a great benefit in manufacturing polymer composites with 80-90 wt.% filler content since they typically demonstrate enhanced performance at considerably lower costs. We describe a low carbon pathway for manufacturing polymer composites with high additive content without the need for external heating that demonstrate similar or better performance than existing market equivalents at lower costs