PV module encapsulants are expected to exhibit optical transparency, mechanical robustness and long-term environmental stability. Polymer-only encapsulants currently used in the photovoltaic industry, such as ethylene-vinyl acetate (EVA), experience gradual photochemical and hydrolytic degradation over the lifetime of the module, leading to performance losses of 1–2% per year in power output. Here we study a family of next generation polymer-ceramic hybrid and bio-inspired nanocomposite encapsulants. Four composite systems are prepared and characterized: (i) EVA with SiO2–TiO2 nanoparticles (0.5–2 wt%), (ii) polyurethane/polyvinylidene chloride (PU/PVDC) matrices with silane-functionalized cellulose nanocrystals (CNCs, 0.1–1 wt%), (iii) vertically aligned ZnO nanowire composites grown on zinc-doped glass substrates, and (iv) a hybrid EVA/SiO2–TiO2/ZnO/CNC film prepared by solvent casting. Mechanical characterization followed ASTM D638 and ISO 180 standards; optical transmittance was measured over 300–1100 nm; and Multiphysics simulation was performed in ANSYS SPEOS under accelerated UV (300–400 nm, 1000 W/m²) and thermal aging cycles (−40°C to 85°C, 85% RH, up to 2000 h). The central hypothesis is that incorporating vertically aligned ZnO nanowires into a CNC-reinforced EVA matrix simultaneously enhances fracture toughness and preserves visible-light transmittance through stress-distribution and photon-alignment mechanisms. Results confirm a 45% improvement in fracture toughness (from 1.2 to 1.74 MPa·m1/2 and 94.5% visible transmittance (400–800 nm) for the EVA/ZnO NW composite, compared to a baseline tensile strength of 3.7 MPa for pure EVA rising to 15.3 MPa for the hybrid EVA/ZnO–SiO₂–CNC formulation. Post-aging elastic modulus retention exceeded 90% after 2000 h for the hybrid composite versus 70–80% for neat EVA, indicating superior durability. These findings establish a scalable, bio-compatible encapsulation strategy adaptable to diverse climatic conditions.
