Gamma irradiation exhibits a complex influence on the properties of PVC/PANI/TiO2 nanocomposite films. XRD analysis reveals a non-monotonic response in crystallinity, with an initial increase at lower doses due to crosslinking followed by a decrease at higher doses attributed to polymer chain scission. Mechanical properties exhibit an improvement in tensile strength and Young's modulus at moderate doses (up to 100 kGy) due to crosslinking. However, excessive irradiation (>100 kGy) induces chain degradation, causing a decrease in both tensile strength and elongation at break. Similar dose-dependent behavior is observed in thermal properties, with moderate doses improving thermal stability and melting temperature before a decline at higher doses due to chain degradation. Gamma irradiation significantly affects AC conductivity, suggesting potential changes in structure, charge carrier density, and conduction mechanisms. While the core chemical structure remains largely unaffected, FTIR and UV–Vis spectroscopy analyses indicate alterations in the degree of crosslinking and optical properties, warranting further investigation. Refractive index increases with irradiation due to enhanced density and changes in polarizability. This study highlights the importance of tailoring the gamma irradiation dose to achieve desired properties in PVC/PANI/TiO2 nanocomposite films for various applications. •γ-Irradiation tailors crystallinity of nanocomposites.•Moderate doses enhance strength & stiffness.•Optimized thermal stability for heat resistance.•Tuned electrical conductivity for electronics.•Balanced optics for light & refractive index.