Quasicrystalline Al-Cu-Fe powders were used as a novel filler material in poly(p-phenylene sulfide) (PPS). These polymer/quasicrystal composites showed useful properties that may be beneficially exploited in applications such as dry bearings and composite gears. Al-Cu-Fe quasicrystalline filler significantly improved wear resistance to volume loss in polymer-based composites. In addition to improving the composite wear resistance, the Al-Cu-Fe filler showed low abrasion to the 52100 chrome steel counterface. Furthermore, mechanical testing results showed a two-fold increase in the storage modulus of the reinforced composites compared with the polymer samples. In addition, the Al-Cu-Fe filler was compared to its constituent metals, aluminum oxide, and silicon carbide in PPS. Chemical analysis of the wear interface by X-ray spectroscopy indicated the generation of a third body oxide layer during wear. The fabrication in addition to the thermal, mechanical, and wear properties of these unique materials is described.