EMC protection through plastics with metallic properties

Electronic systems are everywhere – from complex machine controls and sensor technology in Industry 4.0 to electric drives in vehicle construction. This also increases the risk of electromagnetic interference that can affect other devices or cause sensitive systems to malfunction. Compliance with electromagnetic compatibility (EMC) is therefore essential for the trouble-free functioning of devices and the reliability of sensitive electronic equipment. At Fraunhofer IFAM, we develop innovative functional composites for EMC protection.

Conductive plastics with EMC protection

Traditionally, sensitive electronics are shielded by metal housings, mesh, or coatings. However, these solutions are often heavy, expensive to manufacture, and offer only limited design freedom. The functional composites we have developed on a plastic basis offer a future-oriented alternative. They combine the processability of thermoplastics with the shielding properties of metallic materials. The principle: metallic or carbon-based fillers are specifically incorporated into a plastic matrix. Depending on the type, shape, proportion, and arrangement of these fillers, a material with customized EMC properties is created – e.g., conductive or absorbent.

Customized materials for your application

These composites are manufactured in specially designed extruders at our institute. With state-of-the-art equipment and decades of experience, we offer:

• Individual material selection and formulation development – tailored to your requirements in terms of mode of action, temperature resistance, mechanical stress or processing methods
• Processing of up to five different fillers simultaneously
• Filler contents of over 80% by weight for maximum effectiveness
• Compatibility with almost all common thermoplastics and thermoplastic elastomers
• Special solutions with high-temperature plastics such as PEEK, PEKK, PEI
• Great freedom of geometry thanks to the plastic base

Our expertise ranges from design and mixing and extrusion technology to granulate production and further processing – for example, through injection molding, extrusion, or 3D printing using specially developed filaments. In addition, the institute has a wide range of measuring and analysis equipment at its disposal, e.g., for EMC measurements in accordance with ASTM 4935.

Combination with other functions possible

On request, our composites can also be equipped with additional functionalities:

• Thermal conductivity
• High electrical conductivity
• Magnetic properties

It is also common to combine several functions in one material or to specifically exclude certain properties.

Your benefits at a glance

• Tailor-made EMC protection through targeted material development
• Shielding like metal, but with reduced weight and installation space
• Processing with standard plastics technologies
• Also suitable for high-temperature and elastomer applications
• Combination with other functions possible
• Material characterization according to various standards
• Know-how transfer and training