Syntactic foam has proven to be a good material with a strong structural strength. Understanding filler particle size variation is important in composite material formation especially in syntactic foam because of their numerous applications such as aerospace, marine and structural purposes. In this present work, the effects of particle variation in different sizes (20-24µm, 25-44µm, 45-49µm, and 50-60µm) on the mechanical properties of the syntactic foam composites with focus on flexural strength, modulus, and fracture surfaces were investigated. The particle sizes were varied into five volume fractions (5, 10, 15, 20, and 25vol%). The results shows that highest flexural strength is 89MPa at 5 vol% fraction of 50-60µm particles size variation which is 69% increase than the neat epoxy. This implies that the incorporation of HGM filler volume fraction and size variation has a strong effect on the flexural strength and bending modulus of syntactic foam. The microstructure of the fracture surfaces and the viscoelastic properties was determined and reported accordingly.