ABSTRACT Melt‐spun electrically conductive polymer fibers often face trade‐offs among conductivity, mechanical strength, and processability. This study introduces a synergistic SWCNT/carbon black (CB) hybrid strategy where spherical CB particles appear to maintain connectivity within aligned SWCNT networks. PA6 composites with optimized ratios (PA6/1% SWCNT/3% CB) were systematically characterized for electrical, rheological, thermal, and processing behavior. Percolation thresholds (φc, SWCNT ≈ 0.1–0.25 wt.%, φc, CB ≈ 2–2.5 wt.%) confirmed the superior efficiency of SWCNTs in network formation. The hybrid system maintained resistivity of ∼10 2 –10 4 Ω·cm despite drawing (DDR 2–4), while single‐filler SWCNT systems failed (>10 9 Ω·cm). Complex viscosity (∼1400 Pa·s at 270°C) remained within processable ranges despite elevated values, exhibiting stable shear‐thinning behavior. Mechanical properties showed tenacity of 4–6 cN/dtex with 100%–150% elongation. These structure‐property relationships demonstrate the potential of hybrid nanofiller systems for producing conductive filaments suitable for smart textile applications, positioning hybrid SWCNT/CB systems as promising candidates for scalable smart textile manufacturing.
Kaplan et al. (2026) studied this question.