Carbon nanotube/high density polyethylene (CNT/HDPE) foam composites with high electrical conductivity and electromagnetic interference (EMI) shielding performance were developed by means of compression molding plus salt-leaching. The uniform porous structure and interconnected CNT networks throughout the cell backbones endowed the as-prepared foam composites with a significantly lower electrical percolation threshold (0.22 vol%) than that of the solid composites (0.84 vol%). Owing to the multiple reflections and scattering between the cell-matrix interfaces, the foam composites presented a superior specific EMI shielding effectiveness (EMI SE) of 104.3 dB cm3 g-1, 2.2 times higher than that of their solid counterpart. Besides this, the pore sizes of the CNT/HDPE foam composites could be easily tuned by controlling the particle size of the porogen. Also, the electrical conductivity and specific EMI SE increased with an increase in the cell diameter, which was attributed to the formation of a more perfect conductive network in the cell backbones. Our approach provides a novel idea for fabricating new lightweight EMI shielding materials, especially for aircraft and spacecraft applications.
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