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B. Uma Maheswari,
G.Jeyaram,
Neha Choudhary,
Soundararajan Muthumani,
D. Sudha,
K.Venugopal Rao,
Muthurajan Subramoniam,
Akash Deep Kushwaha,
R.Ashok Gandhi,
- Professor, Department of Computer Science and Engineering, St. Joseph’s College of Engineering, Chennai, Tamil Nadu, India
- Assistant Professor, Department of Computer Science and Engineering (Artificial Intelligence and Machine Learning), Easwari Engineering College, Ramapuram, Chennai, Tamil Nadu, India
- Assistant Professor, Department of Electronics and Communication Engineering, Government Engineering College Vaishali, Vaishali, Bihar, India
- Associate Professor, Department of Civil Engineering, Mahendra Institute of Technology, Namakkal, Tamil Nadu, India
- Associate Professor, Department of Physics, R.M.K. Engineering College, Chennai, Tamil Nadu, India
- Assistant Professor, Department of Electronics and Communication Engineering, Jyothishmathi Institute of Technology and Science, Nustulapur, Karimnagar, Telangana, India
- Assistant Professor, Department of Marine Engineering, Academy of Maritime Education and Training (AMET) Deemed to be University, Kanathur, Chennai, Tamil Nadu, India
- Assistant Professor, Department of Mechanical Engineering, School of Engineering & I.T., MATS University, Raipur, Chhattisgarh, India
- Associate Professor, Department of Mechanical Engineering, Sri Sairam Engineering College, Chennai, Tamil Nadu, India
Abstract
Electrically conductive polymer composites have emerged as promising multifunctional materials for lightweight antenna housings by integrating structural strength, electrical conductivity, thermal stability, and electromagnetic interference shielding. In this study, micro-aluminum reinforced Acrylonitrile Butadiene Styrene (ABS) polymer composites were fabricated using twin-screw melt compounding followed by compression molding for IoT-enabled lightweight antenna housing applications. The influence of micro-aluminum loading on microstructure, mechanical performance, electrical conductivity, EMI shielding, thermal stability, and wireless monitoring was systematically investigated. Scanning electron microscopy revealed uniform particle dispersion and strong polymer-particle interfacial bonding, promoting efficient stress transfer and continuous conductive pathways throughout the polymer matrix. Mechanical characterization demonstrated progressive improvements in tensile strength and flexural strength with increasing filler content. The optimized ABS-Al20 composite achieved an electrical conductivity of 3.85 × 10⁴ S/m and an EMI shielding effectiveness of approximately 38 dB, indicating excellent multifunctional performance. Thermogravimetric analysis confirmed enhanced thermal resistance through the barrier effect of uniformly dispersed aluminum particles. An ESP32-based IoT monitoring system enabled real-time acquisition of temperature, humidity, and vibration data with wireless cloud transmission for continuous structural health monitoring. The developed conductive polymer composite successfully combines lightweight construction, mechanical robustness, electrical functionality, EMI shielding, thermal durability, and intelligent monitoring within a single material platform. These findings demonstrate significant potential for next-generation communication infrastructure, automotive electronics, aerospace systems, smart wireless devices, and advanced IoT applications requiring durable, lightweight, electrically conductive polymer composite materials supporting sustainable high-performance antenna housings with improved reliability, durability, electromagnetic compatibility, and long-term service performance in demanding environments.
Keywords: Acrylonitrile Butadiene Styrene, Thermogravimetric analysis, micro-aluminum, flexural strength, interfacial bonding.
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Journal of Polymer & Composites
| Volume | 14 | |
| 05 | ||
| Received | 17/08/2026 | |
| Accepted | 27/08/2026 | |
| Published | 01/09/2026 | |
| Publication Time | 15 Days |