Highly efficient EMI shielding and Joule heating at low filler loadings via optimization of dispersion and length retention of nickel-plated carbon fiber composites

Ice accumulation and electromagnetic interference (EMI) degrade the efficiency of future mobility platforms. Multifunctional materials providing simultaneous EMI shielding and Joule heating for de/anti-icing are promising solutions. In this study, composites for EMI shielding and Joule heating-based de/anti-icing were fabricated utilizing highly conductive nickel-plated carbon fiber (NCF). To maximize electrical and mechanical properties using the lowest NCF content, processing conditions were systematically investigated to optimize dispersion and preserve NCF length. Consequently, composites fabricated under optimal conditions achieved uniform dispersion and excellent NCF length retention of 3083 µm. Based on these morphological optimizations, the composites exhibited remarkable multifunctional characteristics. With the incorporation of only 5 wt% NCFs, the optimized composite achieved an electrical conductivity of 79.72 S/m, an EMI shielding effectiveness of 49.18 dB, a Joule heating temperature of 129.0 ℃, and a tensile strength of 66.14 MPa. These investigations established structural design rules to secure excellent EMI shielding, Joule heating, and mechanical strength. Finally, the practicality of the fabricated composites was verified through real-world EMI shielding, de-icing, and anti-icing tests. These achievements serve as an important bridgehead for developing next-generation fiber-based multifunctional structural materials.