AbstractThe aim of this research is to evaluate the mechanical and erosion characteristics of stepped polymeric functionally graded materials (PFGMs) reinforced with aluminum particles. By varying the filler content, gradation is achieved along the sample's thickness direction. Three distinct methodologies were adopted in the fabrication of PFGMs; no curing time between the layers (M1), providing curing time between the layers at room temperature (M2) and thermal curing between the layers at 60°C (M3). The results showed that tensile strength and compressive strength of sample M3 increased by 30.3%, 20.8% and 10.3%, 5% as compared to M1 and M2 respectively. The flexural strength of M3 was enhanced by 9% when load direction was from top to bottom (T‐B) than from bottom to top (B‐T). Moreover, the erosion resistance of M3 was higher among all the test samples.