High-performance Electromagnetic Interference Shielding Research Articles

Enhancing the electromagnetic interference shielding performance of composite paper with corrugated paper-like structure

The structural design of material significantly influences its electromagnetic interference (EMI) shielding performance, providing an intelligent approach to attain desirable EMI shielding performances. Inspired by the ultra-large distance of the middle layer in corrugated paper, we proposed a novel composite paper with corrugated paper-like structure via the assembling of two pieces of surface-modified filter paper and an aerogel film. Specifically, a conventional filter paper was modified with the conductive hydrogel film consisting of TEMPO-oxidized cellulose nanofibers (TOCNF), cationic starch (CS) and Ti3C2Tx. The TOCNF and CS rapidly formed a composite hydrogel when mixed, due to their electrostatic interactions. The aforementioned aerogel film was produced through the freeze-drying of TOCNF/CS hydrogel, and it enlarged the distance between two conductive hydrogel film modified papers when inserted. The assembled composite papers demonstrated a maximum EMI SE of 71.0 dB, improved by 19.7 % as compared to the control without the aerogel film (59.3 dB). The expansion of the distance between conductive layers likely facilitated the enhancement in the multiple reflections and absorptions of electromagnetic waves. This novel composite paper showed better EMI shielding performance than many previously-reported materials considering the thickness and conductive filler dosage. In addition, the composite paper also showed exceptional infrared stealth capabilities since it effectively shielded the thermal radiation from human body. The composite paper still exhibited good infrared stealth ability at high temperature conditions (up to 120 ℃). Therefore, this research could inspire innovative concepts in designing high-performance and multifunctional EMI shielding materials in an economical way.

Gradient structured MoS2@MXene/MXene/aramid nanofiber composite film with excellent electromagnetic interference shielding performance

Developing high-performance electromagnetic interference (EMI) shielding materials with robust microwave attenuation capabilities and structural stability remains a formidable challenge to enhance their practical adaptability in everyday scenarios. In this study, we have successfully fabricated a gradient structured MXene-based composite film tailored for high-performance EMI shielding. Initially, a hybrid MoS2@MXene material featuring heterointerfaces is synthesized, which exhibits exceptional electromagnetic wave (EMW) absorption capabilities. Subsequently, a gradient structured multi-layer film is engineered using a layer-by-layer casting approach, gradually increasing the MXene content in the MoS2@MXene/MXene/aramid nanofiber composite. This composite film is purposefully designed to employ an “absorb-reflect-reabsorb” EMI shielding mechanism, resulting in reduced reflection power. The resultant composite film achieves an impressive EMI SE of 50.9 dB, coupled with remarkable structural stability persisting through 500 folding cycles. This study presents a viable and potent strategy for developing flexible, absorption-dominant EMI shielding materials.

Ultrathin-flexible multifunctional MXene composite hydrogels with good mechanical properties-high strain sensitivity and ultra-broadband EMI shielding performances

Conductive hydrogels show excellent application potential in flexible and stretchable electromagnetic interference (EMI) shielding materials due to their water-rich porous structure and tissue-like mechanical properties. However, integrating multiple functions into EMI shielding materials remains challenging, including ultra-broadband EMI shielding, mechanical properties, strain sensitivity, flexibility, etc., with high performance. Here, through a straightforward and scalable combination of ultrasound-assisted dispersion and thermal polymerization, we have successfully synthesized the MXene/PE-CS composite hydrogels composed of acrylic acid (AA), 2-(Dimethylamino) ethyl methacrylate (DMAEMA), and chitosan (CS). It exhibits more comprehensive and excellent functionalities including high stretchability (0.47 MPa, 747 %), strain sensitivity (11.2), ultralow thickness (0.5–2.0 mm), good adhesion (0.13 MPa), and flexibility. More importantly, it achieves excellent shielding performance of more than 99.99 % in ultra-broadband (X-band, Ka-band, Ku-band, and THz-band) under ultralow thickness (0.5–2 mm) and MXene (transition metal carbides/nitrides) content (0.46 wt%), and the shielding properties can be dynamically controlled through MXene content, PE content and hydrogel thickness. Even after repeated stretching, bending, and long-term water evaporation, it still exhibits stable and high-performance EMI shielding performance. Our MXene/PE-CS composite hydrogels exhibit potential applications in ultra-broadband shielding for new generation flexible wearable electronic devices.

Flexible conductive polymer composite film with sandwich-like structure for ultra-efficient and high-stability electromagnetic interference shielding

Flexible electromagnetic interference (EMI) shielding films with the merits of light-weight, flexibility, and high EMI shielding performance are the essential materials for the consumer electronics and communication products. Herein, we construct a hybrid conductive network based on the electrospinning thermoplastic polyurethane (TPU) film loaded with different dimensional conductive fillers, including 0D FeCl3, 1D carbon nanotube (CNT) and 2D graphene nanosheet (GN) to achieve a flexible, light-weight, and ultra-efficient EMI shielding composite film. In specific, the electrospinning porous TPU film is firstly anchored by CNTs assisted by ultrasound to generate the porous TPU/CNT film. Thereafter, the as-prepared porous TPU/CNT film is loaded a GN/CNT/FeCl3 layer by vacuum-assisted filtration to generate a double-layer GN/CNT/FeCl3@TPU/CNT film. Finally, another porous TPU/CNT film is sealed onto the GN/CNT/FeCl3@TPU/CNT film by hot-pressing, which fabricates a sandwiched TPU/CNT@GN/CNT/FeCl3@TPU/CNT composite film. It is interesting to note that the composite film possesses the ultrahigh EMI shielding value (56.0 dB at 10.0 GHz) in the X-band (8.2–12.4 GHz) with high flexibility, excellent mechanical properties, long-term durability (acid-base environment resistance and stability after 1000 bends), as well as high thermal conductivity (6.53 W/(m.K)). This work proposes a simple but efficiency strategy to design the flexible EMI shielding film with ultra-high performance and outstanding durability.

Advanced Polymer Composite with Graphene Content for Emi Shielding

One of the increasingly common unexpected outcomes of the extensive usage of electronic devices and systems is electromagnetic interference (EMI). The need for efficient fillers and shielding materials to manage electromagnetic interference (EMI) and associated issues is rising. Adding more filler typically means greater production costs, poor dispersion, and unintended agglomeration, which makes polymer composites harder to work with and mechanically weak. Therefore, it is highly desired to design a strong composite with conductive filler content that nonetheless performs well as an EMI shield. Therefore, using a graphene substrate and dispersion of conducting polymers such as polyacetylene and MWCNT fillers, a hybrid polymer composite based on polyetherimide is proposed in this research. Next, the enhancement of EMI shielding efficiency is examined. The design of the graphene substrate was completed with a coating based on nano filler, and the blending methods of the polymer matrix and the reinforcing filler materials are explored. ANSYS-HFSS software is then used to assess the shield's efficacy among others, and the results demonstrated improved performance. Therefore, by putting the suggested design into practice, high-performance EMI shielding materials can be created by combining various shield fillers. As a result, the composites' mechanical, electrical, and EMI shielding qualities will all improve.

Design and Analysis of a Textured Cu-Encapsulated Ni Tube for Low-Reflection Electromagnetic Interference Shielding Material.

With the frequent increase and update of electromagnetic interference (EMI) shielding materials, a low-resolution material that can absorb most electromagnetic waves, thereby effectively reducing the secondary pollution, is urgently needed. However, the excellent performance, flexibility, and low cost of these methods are usually incompatible with current reports. To address the above dilemma, we reported a facile solution for fabricating a low-reflection and high-performance EMI shielding composite by means of electroless nickel plating (EP-Ni), electroless copper plating (EP-Cu), annealing, and coating with a polydimethylsiloxane (PDMS) polymer with the structure of a Ni@Cu tube encapsulated with PDMS. The results indicate that the active groups on vegetable wool can act as active sites for the absorption of the Pd catalyst, thereby catalyzing the reduction of Ni2+, Cu2+, and the subsequent deposition on the plant fiber surface. Notably, the Ni@Cu-encapsulated plant fibers decreased during annealing at 100 °C. According to the segregated network and synergistic effect of the porous structure, the as-fabricated EMI shielding material demonstrated high absorption and low reflection, in which the power coefficient of the T value was approximately 0.0001, the R value was about 0.1764 (a decrease of 27.5% compared that of EP-Ni cotton), and the A value was approximately 0.8235.

Electromagnetic interference shielding composite aerogels with asymmetric structures developed in aid of neural network

Along with the increasingly serious electromagnetic interference (EMI) pollution, it is in urgent need of exploiting high-performance EMI shielding materials. However, the conventional experimental methods always require a series of tedious preparation and characterization processes, resulting in the long period and high cost. Herein, a fully connected neural network (FCNN) was applied to aid in exploiting silver nanowires/waterborne polyurethan/multi-walled carbon nanotubes (AgNWs/WPU/MWCNTs) EMI shielding aerogels with asymmetric structures to optimize new material evolution and reduce experiment burden. Firstly, the special AgNWs/WPU/MWCNTs aerogels were fabricated with various MWCNTs content (0 wt%, 2 wt%, and 4 wt%) and AgNWs mass (10 mg, 20 mg, 30 mg, and 40 mg) via a combination of directional freezing and spraying procedures, leading to 12 distinct samples. AgNWs/WPU/MWCNTs aerogels hold excellent EMI shielding properties and absorption-dominant shielding mechanism. The experimental EMI shielding effectiveness (SE) data at different frequency were leveraged to establish, train, and test the FCNN model based on Adam optimizer (Adam-FCNN). It is worth noting that Adam-FCNN model predictions are in good accordance with the EMI SE of the physically measured samples, with the lowest root mean square error RMSE of 0.7899, the highest correlation coefficient (R) of 0.9895, and excellent computational efficiency and reliability. Moreover, Adam-FCNN can accurately prognosticate EMI SE of unobtained AgNWs/WPU/MWCNTs aerogels in mechanics-intuitions to reduce repeated preparation and characterizing conditions. Thereby, Adam-FCNN soft model approach opens significant potential for alleviating the experimental burden, accelerating the discovery of innovative materials, and exploring the complex mechanism.

Flexible regenerated cellulose composite films with sandwich structures for high-performance electromagnetic interference shielding

Flexible regenerated cellulose composite films with sandwich structures for high-performance electromagnetic interference shielding

INTERCALATING POLYMER WITH NANO STRATUM GRAPHENE FOR EMI SHIELDING

Electromagnetic interference (EMI) has been identified as one of the ever-increasing unintended consequences of the widespread use of electronic devices and systems. There is a growing demand for effective shielding materials and fillers to control EMI and related concerns. Increased filler content usually results in higher costs, poor dispersion, and unwanted agglomeration, making polymer composites mechanically fragile and difficult to produce. As a result, developing a robust composite with conductive filler content while maintaining good EMI shielding performance is extremely desirable. Hence in this paper, a hybrid polymer composite based on polyetherimide is suggested by dispersion of conducting polymers like polyacetylene and MWCNT fillers with a Graphene substrate. Then the improvement in EMI shielding effectiveness is investigated. The blending techniques of the polymer matrix and the reinforcing filler materials are discussed and the design of the Graphene substrate was done with a nano filler based coating on it. The effectiveness of the shield is then analyzed with ANSYS-HFSS software. S-parameters of the shield like S11, S12, and S21, etc. are determined using the plots obtained and this showed superior performance. Hence by implementing the proposed design the high-performance EMI shielding materials can be fabricated by the combination of different fillers for the shield. This will improve the electrical, mechanical, and EMI shielding properties of the composites.

Durable and sustainable CoFe2O4@MXene-silver nanowires/cellulose nanofibers composite films with controllable electric–magnetic gradient towards high-efficiency electromagnetic interference shielding and Joule heating capacity

Exploring electromagnetic waves (EMW) absorption-dominated high-performance electromagnetic interference (EMI) shielding materials with robust mechanical properties and remarkable Joule heating capability is highly desired but remains a daunting challenge for the development of modern electronic equipment. Herein, durable and multifunctional cellulose nanofiber-based composite films with elaborate electric–magnetic dual gradient structure were successfully fabricated through highly controllable vacuum-assisted filtration technology. The electric–magnetic dual gradient network consists of CoFe2O4@MXene hybrids with electric–magnetic cooperative loss concentrated on the top region as impedance matching layer and silver nanowires (AgNWs) with high conductivity placed on the bottom as high-efficiency shielding layer. Benefiting from the construction of dual gradient network with rational arrangement of the impedance matching layer and conductive shielding layer, the synergy of electric–magnetic loss, polarization loss induced by the numerous heterointerfaces and “absorption-reflection-reabsorption” shielding mechanism, the resultant composite films simultaneously reveal ultraefficient EMI shielding effectiveness (SE) and low EMW reflectivity. The prepared composite films (0.1 mm in thickness) achieve an extraordinary EMI SE of 84.3 dB and a satisfactory reflection coefficient of 0.42, realizing EMW absorption-dominated shielding feature. Moreover, the mechanical properties and Joule heating capacity of the prepared composite films are outstanding, which mainly benefits from the construction of hierarchically layered structure. This work paves a novel route for designing and fabricating absorption-dominated high-performance EMI shielding composite films with durable mechanical performance and outstanding Joule heating capability, which are potentially suitable for new-generation advanced electronics.

Ti3C2Tx MXene- and Sulfuric Acid-Treated Double-Network Hydrogel with Ultralow Conductive Filler Content for Stretchable Electromagnetic Interference Shielding.

Hydrogels are emerging as stretchable electromagnetic interference (EMI) shielding materials because of their tissue-like mechanical properties and water-rich porous cellular structures. However, achieving high-performance hydrogel shields remains a challenge because enhancing conductivity often results in a compromise in deformation adoptability. This work proposes a treatment strategy involving sulfuric acid/titanium carbide MXene, which can simultaneously enhance the conductivity and stretchability of poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS)/poly(vinyl alcohol) (PVA) double-network hydrogels. Multiple spectroscopic characterizations reveal that sulfuric acid promotes the linear conformation transition of the PEDOT molecular chain, while MXene increases charge delocalization and hydrogen bond cross-linking sites. The hydrogels, synthesized with a combined content of 0.6 wt % of MXene and PEDOT:PSS, exhibit an average X-band EMI SE of 41 dB. This performance is sustained at 94.5%, even following stretching and release at a strain of 200%. Interestingly, the EMI SE is found to linearly increase, reaching a value of 99 dB as the frequency is increased to 26.5 GHz. This increase is attributed to the enhanced water molecular polarization process, as supported by theoretical calculations of the impedance and attenuation constant. This work introduces a post-treatment technique that optimizes double-network hydrogels, providing deep insights into their EMI shielding mechanism and enabling high-performance EMI shielding with an ultralow conductive filler content.

Catechol grafted rGO/MXene heterosheet structures for high performance electromagnetic interference shielding and thermal management applications

Two-dimensional MXenes have shown extraordinary potential in various scientific areas, including energy harvesting and microwave shielding. Despite their outstanding properties, MXene-based scaffolds suffer from vulnerable mechanical fragility and environmental instability, which reduces the operational life. Here, we used a nature-inspired strong surface adhesion to assemble a stacked heterosheet structure of reduced graphene oxide (rGO) and MXene (Ti3C2TX). Catechol bonding of self-triggered polydopamine between these two-dimensional nanofillers resulted in a dense and well-ordered structure, transforming their mechanical and electrical properties to those of a freestanding sheet. The simultaneous grafting of catechol and the formation of stacked heterosheets with rGO not only protects the MXene sheets from environmental oxidation but also preserves their intrinsic transportation properties. The resulting rGO/MXene composite sheet was ordered and dense, with a tensile strength of 86 MPa and toughness 118.2 MJm−3. The ultrathin, highly flexible, and conductive (26.5 Scm−1) composite sheet exhibited specific shielding effectiveness of 16340, 19136 and 21340 dBcm2g−1 in the X, Ku, and K bands, respectively. Additionally, it showed outstanding Joule-heating properties, with a rapid thermal response of approximately 2 s and the ability to reach a saturation temperature >120 °C at a relatively low supplied voltage of <7 V. The grafted rGO/MXene composite sheet maintained its transportation properties, electromagnetic interference shielding, and electrothermal properties even after 60days of continuous exposure to ambient by suppressing oxidation attacks. The synergistic enhancement of physical properties and environmental stability in the composite sheet suggest a great potential for high-performance, flexible shielding, and thermal management applications in aerospace and automobile electronics.

High-performance low-profile green electromagnetic interference shielding material for 5G mm-wave using characteristic mode theory

With the rapid development of 5G communication technology, high-frequency electromagnetic interference (EMI) shielding plays a vital role in the normal operation of electrical and electronic equipment and systems, and has attracted surging interest in 5G mm-wave applications. However, many current EMI shielding materials contain highly conductive materials, resulting in strong secondary reflection and environmental pollution. Here, we propose a green high-performance EMI shielding material for 5G mm-wave based on a metamaterial absorber (MMA). Characteristic mode theory and equivalent circuit are employed to inversely design the unit cell’s dimension and structure, as well as the resistive value of the proposed MMA. We reveal that from 22 to 43.5 GHz, the shielding effectiveness of higher than 30 dB, and the standard green index of SER < 3.01 dB and g s ⩾ 1 can be realized whether the MMA is flat or even bent. Excellent agreement between the measured and simulated results verified the high performance of the proposed EMI shielding MMA. The transmittance of over 85.84% can be achieved within the 380 ∼ 800 nm spectrum. The proposed green EMI shielding material integrates multi-functionalities of low profile, flexibility, polarization-insensitiveness, wide-angle, and optical transparency, and can find potential applications in EMI shielding in complex electromagnetic environments.

Lightweight ZnO/Carbonated Cotton Fiber Nanocomposites for Electromagnetic Interference Applications: Preparation and Properties.

Electromagnetic wave pollution has become a significant harm posed to human health and precision instruments. To shelter such instruments from electromagnetic radiation, high-frequency electromagnetic interference (EMI) shielding materials are extremely desirable. The focus of this research is lightweight, high-absorption EMI shielding composites. Simple aqueous dispersion and drying procedures were used to prepare cotton fiber (CF)-based sheets combined with various zinc oxide (ZnO) contents. These composites were carbonated in a high-temperature furnace at 800 °C for two hours. The obtained CF/ZnO samples have densities of 1.02-1.08 g/cm3. The EMI shielding effectiveness of CF-30% ZnO, CF-50% ZnO, and CF-70% ZnO reached 32.06, 38.08, and 34.69 dB, respectively, to which more than 80% of absorption is attributed. The synergetic effects of carbon networks and surface structures are responsible for the high EMI shielding performance; various reflections inside the interconnected networks may also help in improving their EMI shielding performance.

Dual cross-linked and vertically oriented MXene/polyvinyl alcohol aerogel for ultrabroadband electromagnetic interference shielding and thermal camouflage

Lightweight and porous conductive aerogels have demonstrated great potential in electromagnetic interference (EMI) shielding and thermal camouflage, while the poor mechanical properties and structural stability usually limit their applications. Herein, vertically oriented and physically/chemically dual cross-linked Ti3C2TX MXene/polyvinyl alcohol (PVA) composite aerogel is prepared by ice-templated unidirectional freezing process and subsequent glutaraldehyde (GA) treatment. GA induced covalent crosslinking leads to the significantly enhanced structural stability and mechanical strength of the resultant MXene/PVA composite aerogels, which also endows them with desirable flame retardancy. The honeycomb-like structure of the composite aerogel contributes to its good anisotropic absorption-dominated EMI shielding performance over an ultrabroadband frequency range (8.2–40 GHz) with a low MXene content of 3.81 vol%. Furthermore, the excellent thermal insulation properties and low infrared emissivity of the highly oriented arranged MXene sheets bring the composite aerogel promising applications in thermal camouflage. Therefore, the lightweight and robust MXene/PVA composite aerogel demonstrates great potential in multi-scenario applications as a high-performance multifunctional EMI shielding material.

Exoskeleton-like mechanical enhanced low-density aerogel with electromagnetic interface shielding and infrared stealth

The integrated design and mechanical enhancement of multifunctional electromagnetic interference shielding and infrared stealth aerogels are challenging for the development and application of novel aerogels. Here, inspired by the biological exoskeleton to enhance the body, we develop the exoskeleton-like aramid nanofiber/polyimide/MXene (APM) aerogel through a secondary impregnation strategy. For APM aerogel, the polyimide reinforcement layer makes the aerogel more elastic and tough; the Ti3C2Tx-MXene exoskeleton enhances the strength and stiffness of the aerogel. Importantly, Ti3C2Tx-MXene forms a continuous conductive network on the surface of the airgel backbone, resulting in high-performance electromagnetic interference (EMI) shielding (EMI shielding efficiency reached 55.315 dB at an ultra-low Ti3C2Tx content of 0.58 vol%), high-efficiency infrared radiation (IR) stealth (ultra-low thermal conductivity of 0.0666 W·m−1·K−1 and IR emissivity of 0.566 at 3–5 μm and 0.55 at 8–14 μm). This study provides a way to design robust aerogel materials with infrared stealth and electromagnetic shielding compatibility.

Stretchable textile with ultra-high electromagnetic interference shielding performance based on porous wrinkled conductive network

The soaring growth of flexible electronic devices has boosted the demand for electromagnetic interference (EMI) shielding materials with excellent stretchability, stability and even breathability. However, it is still a challenge to develop conductive materials with outstanding stretchable EMI shielding performance. In this work, we developed a textile with porous wrinkled conductive network through in situ polydopamine-assisted deposition of silver nanoparticles (AgNPs) on wrinkled fiber mat and polydimethylsiloxane post modification. This unique wrinkled conductive networks endows the textile with excellent electrical conductivity (103700 S/m), good breathability, superhydrophobicity, and ultra-high stretchable EMI shielding properties. The EMI shielding effectiveness (EMI SE) of the textile reaches 101.1 dB in unstretched state and still maintains at 94.1 dB at 100 % tensile strain. The superhigh EMI SE under such a high strain is much higher than the previously reported results so far. Moreover, the textile shows exceptionally good cyclic tensile durability under 100 % stain. After 1000 tensile cycles with 100 % strain, the EMI SE of sample only drops by 3.8 %. This work provides a new path for developing stretchable high EMI shielding performance materials, which is of great significance to solve the EMI problems of emerging flexible and wearable electronic devices.

Effective electromagnetic interference shields based on cellulose nanofibers-carbon nanotubes layered composites

The rapid development of electronic devices and communication technologies has inadvertently led to the production of significant amounts of Electromagnetic Interference (EMI) and radiation, necessitating the development of sustainable, low-density, affordable, and high-performance EMI shielding materials. The present study involves fabricating a layered composite material comprising alternating substrate and conducting layer made primarily of TEMPO-mediated oxidized cellulose nanofibers (TCNF) and carbon nanotubes (CNT). For the substrate layer, TCNF is modified with optimized polydopamine and Fe3+ concentrations to produce mechanically strong film with a tensile modulus of 12.3 GPa. Furthermore, two CNT/TCNF ratios are used in the conducting film: 60% and 80%. In addition to absorption and reflection, the presence of TCNF in the conducting layer creates an impedance mismatch, resulting in a zigzag reflection mechanism for EMI losses. For a thickness of 212 μm, the 5-layered composite exhibited a notable tensile strength of 58 MPa and an efficient EMI shielding effectiveness (EMI SE) of 39 dB in X-band. The prepared composites meet the requirements for a commercial EMI shielding material, namely >20 dB, and outperform the mechanical strength of many other EMI shielding materials.

Flexible Graphene/MXene Composite Thin Films for High-Performance Electromagnetic Interference Shielding and Joule Heating

Flexible Graphene/MXene Composite Thin Films for High-Performance Electromagnetic Interference Shielding and Joule Heating

Real-microcellular poly(ether-block-amide)/carbon fiber foams with improved mechanical property and surface quality for high-performance electromagnetic interference shielding applications

Challenges remain in large-scale and successive preparation of porous polymer composite component, which limits its practical applications for high-performance electromagnetic interference (EMI) shielding. Herein, a scalable and efficient method based on mold-opening foam injection molding was developed to fabricate carbon fiber (CF) reinforced polymer composite foams for EMI shielding applications. Thanks to the novel foaming process and heterogeneous nucleation effect of CF, real microcellular poly(ether-block-amide) (PEBA)/CF composite foams with an average cell size of 6.6 μm and a cell density of up to 109 cells/cm3 were achieved. Due to the significantly refined cellular morphology, the PEBA/CF composite foams exhibit superior EMI shielding performance over the unfoamed composites which was characterized by absorption-dominated shielding characteristics and significantly enhanced EMI shielding effectiveness. Furthermore, compared with the unfoamed case, the foamed PEBA/CF composites with refined cellular morphology shows greatly improved cold toughness and duality, and the tensile strain at break and specific tensile toughness are increased by 88.6% and 109.1%, respectively. Moreover, real-microcellular PEBA/CF composite foams have remarkably enhanced surface quality than those fabricated by regular foam injection molding process, and the surface roughness can be maximumly increased by 91.6%. Thus, this study provides a promising strategy for producing lightweight and strong components for high-performance EMI shielding applications.