Investigation of conductive hybrid polymer composites reinforced with copper micro fibers and carbon nanotubes produced by injection molding

•The new injection moldable plastics could replace conductive components.•Hybridization improved conductivities compared to metal filled composites significantly.•Hybridization improved the surface integrity and reduced the roughness values.•Nano bridges between the micro gaps among metal fillers enhanced the conductivities.•Hybridization led to novel multi-functional materials. Conductive polymeric composites have proved themselves invaluable for novel manufacturing and applications. In this paper, production and properties of injection moldable conductive plastics to replace metal circuits especially in micro components are investigated. Polymeric composites containing conductive micro and nano fillers are designed and characterized experimentally and numerically. Results show that hybridization of Copper micro fibers and carbon nanotubes enhances the conductivity properties two orders of magnitude while reducing the weight and cost of the composites. Moreover, the new injection moldable conductive plastics show improved mechanical and surface properties. The research endeavors to provide novel multifunctional solutions for future components with complex geometries.