Direct Ink Writing of Flexible Conductive Polymer Aerogels with Exceptional Electromagnetic Shielding Efficiency

In this work, a strategy for synthesizing highly conductive poly(3,4-ethylenedioxythiophene) polystyrenesulfonate (PEDOT:PSS) aerogel films through additive manufacturing, specifically using the direct ink writing (DIW) method, is demonstrated. This approach marks the first application of pure PEDOT:PSS aerogels in electromagnetic interference (EMI) shielding, employing PEDOT:PSS as the sole matrix material without additives. The synthesis enabled by DIW achieves aerogels with over 90% porosity and an electrical conductivity surpassing 10 S cm–1. The films exhibit outstanding EMI shielding effectiveness in the X and Ku bands, achieving shielding effectiveness above 100 dB and specific shielding effectiveness approaching 15,000 dB cm2 g–1. The aerogels also show remarkable environmental resilience, maintaining their conductive properties after extensive exposure to high humidity, multiple water soak and dry cycles, and temperatures up to 200 °C without degradation in shielding efficiency. Additionally, by modifying the hydrogel precursor formulations, the aerogels’ mechanical flexibility is enhanced with minimal impact on their EMI shielding performance. This research not only underscores the capabilities of PEDOT:PSS aerogels as a viable material for EMI shielding but also highlights the critical role of additive manufacturing via DIW in developing adaptable and robust shielding solutions for diverse environmental conditions.