3D Printed Nanotube Composite for EMI & Radiation Shielding

There’s no shortage of “breakthrough materials” in nanotech, although many never leave the lab. But every so often, something appears that looks less like a science experiment and more like a commercial opportunity waiting for the right partner.

A recent development in 3D-printable nanotube–polymer composites might be one of those moments.

The discovery was made at the Korean National University of Science and Technology (UST) and involves the use of ultrathin, stretchable composites built with carbon nanotubes. On paper, that’s nothing new, as numerous composites have been made with nanomaterials to provide added strength, flexibility, and even electrical conductivity. What is new this time is that it includes this combination of properties:

· Effective shielding against electromagnetic interference (EMI).

· Protection from neutron radiation.

· Mechanical flexibility, low weight, and an ultrathin structure.

· Compatibility with additive manufacturing processes.

It is a union of characteristics with great significance for manufacturers, as in real-world engineering, what a product is made of plays a key role in its success or failure. Choosing the correct raw material is difficult, because if it is sufficient in one property, then they often lack in another. One feedstock may be flexible enough, but it can also be too soft. Another is very durable but too fragile, another is strong enough but too expensive.

For products which require both EMI shielding and radiation protection this is a significant challenge, as they traditionally require different materials, different layers, and each new ingredient adds more weight.

Now nanotechnology is offering an approach which compresses those functions into a single, flexible composite. This means fewer layers, less complexity, and lower weight.

The discovery is based on the ability to blend different nanomaterials to resolve different requirements. As a recent report in the nanotechnology journal AzoNano explains, “The material system is built around two nanotube types with different strengths. Single-walled Carbon Nanotubes (SWCNTs) are electrically conductive and effective at attenuating electromagnetic waves. Boron nitride nanotubes (BNNTs), meanwhile, contain boron atoms with a high neutron absorption cross-section, making them well-suited to neutron shielding.” To make the composite, “The team first dispersed SWCNTs and BNNTs in solution using surfactants to produce stable suspensions and uniform mixing. Free-standing hybrid films were then made by vacuum filtration, yielding structures typically 10 to 20 µm thick.”

Microscopy showed that the composite included a coaxial design with SWCNT bundles encircling BNNT cores, while elemental mapping verified the distribution of boron, nitrogen, and carbon throughout the hybrid structure.

“To make printable composites, the researchers then incorporated the nanotube network into a polydimethylsiloxane (PDMS) elastomer matrix,” the report adds. “The resulting ink was processed by direct ink writing, an extrusion-based 3D-printing method that enables layer-by-layer fabrication of complex geometries. Rheological testing showed that the ink had the viscoelastic properties needed for printing.”

Unlike many early-stage nanomaterial innovations, the end-use here is relatively obvious, with aerospace and satellite systems representing a natural fit. As weight reduction in this field remains a primary cost driver, multifunctional materials that can provide sufficient shielding while reducing mass can deliver immediate value.

Defence and nuclear electronics also present strong opportunities, as resistance to radiation is essential in these environments, and combining this with EMI shielding addresses two critical requirements simultaneously.

Beyond these sectors, high-performance electronics continue to face increasing EMI challenges as devices become more compact and powerful. Similarly, electrification trends in automotive and energy systems are also driving demand for more effective shielding solutions.

Related articles: Stretchy, Conductive Polymers for Smart Manufacturing or Where Nanostructured Polymers are Advancing Industry

The compatibility of these nanomaterial composites with 3D printing is also noteworthy, as it enables the integration of shielding directly into component design, rather than relying on secondary materials or assemblies. This allows for more efficient use of space, greater design flexibility, and potential reductions in assembly steps.

In each of these cases, the decision to use the technology is not driven by the presence of nanomaterials but by cost-assessed improvements in efficiency. This represents another situation where the inclusion of nanotechnology is carried out due to clear benefits which conventional feedstocks cannot provide to the same degree.

For material suppliers and compounders, this is evidence of a shift in manufacturing towards offering higher value. Instead of supplying traditional raw materials, there is an opportunity to deliver application-specific solutions which combine material performance with design functionality.

It’s easy to get distracted by the buzz around nanotechnology. But markets don’t reward novelty—they reward usefulness.

The manufacturers that succeed in this evolving market won’t necessarily be the ones with the most advanced nanotechnology. They’ll be the ones who solve specific problems, deliver consistent materials at scale, and fit into existing manufacturing workflows without friction.

Nanotube composites like these won’t transform entire industries overnight. But in the right niches—where performance outweighs cost—they don’t need to.

For POLYMER NANO CENTRUM, this type of development aligns closely with its central goals—the use of nanotechnology to solve challenges in manufacturing.

By combining expertise in polymers and nanomaterials, the company (which hosts this webpage) is in a position to support companies in their transition from research to application. This may include material testing, process optimisation, and the development of tailored composite systems for specific product solutions. By acting as an intermediary between innovation and industrial deployment, POLYMER NANO CENTRUM is providing value in a world where raw materials are becoming increasingly complex.

To learn more about what POLYMER NANO CENTRUM does and how it can use nanotechnology to solve a specific manufacturing problem, contact info@polymernanocentrum.cz or visit POLYMER NANO CENTRUM.

Photo credit: juicy_fish, Wikimedia, Raw Pixel, & wayhomestudio