Magnetic Metal–Polymer Composites with Ferromagnetic Particle Networks for EMI Shielding in Flexible Electronics

Year : 2026 | Volume : 14 | Issue : 01 | Page : 25 39
    By

    Kedri Janardhana,

  • P. Suresh Kumar,

  • Santhi M George,

  • B Karthik,

  • P.Duraipandy,

  • Kode Jaya Prakash,

  • Gadhamsetty Gurumahesh,

  • Sathish Rengarajan,

  • Sekar K,

  1. Assistant Professor (Selection Grade), Department of Electrical Engineering, Faculty of Engineering, Dayalbagh Educational Institute (Deemed to be University), Agra, Uttar Pradesh, India
  2. Associate Professor, Department of Mechanical Engineering, R. V. R & J. C. College of Engineering, Guntur, Andhra Pradesh, India
  3. Associate Professor, Department of Science and Humanities, R.M.K. Engineering College, Kavaraipettai, Tamil Nadu, India
  4. Associate Professor, Department of Electrical and Electronics Engineering, Sona College of Technology, Salem, Tamil Nadu, India
  5. Associate Professor, Department of Electrical and Electronics Engineering, J. B. Institute of Engineering and Technology, Hyderabad, Telangana, India
  6. Senior Assistant Professor, Department of Mechanical Engineering, VNR Vignana Jyothi Institute of Engineering & Technology, Hyderabad, Telangana, India
  7. Associate Professor, Department of Mechanical Engineering, Sri Venkateswara College of Engineering, Tirupati, Andhra Pradesh, India
  8. Professor, Department of Mechanical Engineering, St.Joseph’s College of Engineering, OMR, Chennai, Tamil Nadu, India
  9. Professor, Department of Electrical and Electronics Engineering, Adithya Institute of Technology, Coimbatore, Tamil Nadu, India

Abstract

The rapid expansion of flexible and wearable electronic systems has intensified the demand for lightweight, mechanically compliant materials capable of effective electromagnetic interference (EMI) shielding. In this study, magnetic metal–polymer composites with magnetically aligned ferromagnetic particle networks were developed and systematically investigated for EMI shielding in flexible electronics. Thermoplastic polyurethane (TPU) was employed as an elastomeric polymer matrix due to its excellent flexibility, dielectric characteristics, and compatibility with particulate fillers. Ferromagnetic Fe₃O₄ and Ni fillers were incorporated and aligned using a magnetic field-assisted assembly strategy to transform the polymer composite architecture from a randomly dispersed particulate system into a network-dominated functional composite. Magnetic, electrical, mechanical, and EMI shielding properties were evaluated to establish clear structure–property relationships. The aligned polymer composites exhibited enhanced saturation magnetization and reduced electrical percolation thresholds, confirming efficient network formation within the polymer matrix. EMI shielding effectiveness exceeded 40 dB in the X-band (8–12 GHz) at optimized filler loadings, corresponding to over 99.99% electromagnetic attenuation. Importantly, shielding was dominated by absorption rather than reflection, arising from synergistic magnetic losses, interfacial polarization, and polymer dielectric dissipation. Despite increased stiffness at higher filler contents, the polymer composites retained high elongation at break (>300%), demonstrating excellent flexibility and mechanical durability. Overall, the results highlight that polymer composite architecture, rather than filler content alone, governs EMI shielding performance. The combination of elastomeric TPU matrices and magnetically engineered ferromagnetic networks provides a scalable and mechanically robust pathway for next-generation flexible EMI shielding materials.

Keywords: EMI shielding, ferromagnetic networks, flexible electronics, metal–polymer composites, shielding properties

[This article belongs to Journal of Polymer & Composites ]

How to cite this article:
Kedri Janardhana, P. Suresh Kumar, Santhi M George, B Karthik, P.Duraipandy, Kode Jaya Prakash, Gadhamsetty Gurumahesh, Sathish Rengarajan, Sekar K. Magnetic Metal–Polymer Composites with Ferromagnetic Particle Networks for EMI Shielding in Flexible Electronics. Journal of Polymer & Composites. 2026; 14(01):25-39.
How to cite this URL:
Kedri Janardhana, P. Suresh Kumar, Santhi M George, B Karthik, P.Duraipandy, Kode Jaya Prakash, Gadhamsetty Gurumahesh, Sathish Rengarajan, Sekar K. Magnetic Metal–Polymer Composites with Ferromagnetic Particle Networks for EMI Shielding in Flexible Electronics. Journal of Polymer & Composites. 2026; 14(01):25-39. Available from: https://journals.stmjournals.com/jopc/article=2026/view=236218


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Regular Issue Subscription Original Research
Volume 14
Issue 01
Received 20/12/2025
Accepted 07/01/2026
Published 17/01/2026
Publication Time 28 Days
22

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