The main goal of the work presented in this paper is to develop and characterize a manufacturing process that introduces a novel technology for manufacturing magnetic polyvinylchloride (PVC) nanocomposites, from stacked PVC foils, with intermediate sandwiched layers of uniformly dispersed ferro magnetic nanoparticles, by means of solid-state surface ultrasonic welding. Laboratory analysis of nanocomposite samples to investigate their behavior, is performed by microscopic, magnetic, and mechanical testing. Transmission electron microscopy (TEM) and scanning electron microscopy (SEM) are employed for measuring nanoparticle dispersions and their distribution in the polymer matrix. The magnetic properties of the composites are measured by a physical property measurement system (PPMS), while mechanical behavior is studied by dynamic mechanical analyzer (DMA) and a universal mechanical testing system. The resulting materials are nanocomposite foils with very high ferromagnetic behavior.