I have used melt blending to prepare a nanocomposite. Cryomicrotome can be used to make a flat surface on a compression molded sample, but it is an expensive method. I need an easy and low cost method!
You can use various polishing techniques. (Comapnies like Struers, Buehler etc provide a series of automated and manual polishing machines and accessories)
First check the roughness of your sample using piezo imaging. If it is greater than 500 nm start with coarse polishing using SiC sheets. It will reduce your roughness value to less than 500 nm. Then using varying sizes of diamond particles (6-1 micon) in a lubricant medium you can gradually reduce the roughness to less than 50 nm.
For more details refer:
http://www.struers.com/Knowledge/Grinding-and-polishing/#
You should polish your samples after impregnating them in a resin.
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