Abstract The present study is on the fabrication of epoxy nanocomposites for electromagnetic interference (EMI) shielding in the X‐band and Ku‐band frequency range. Single‐layer unidirectional carbon fiber along with nano zirconia is used to achieve the required EMI shielding and mechanical strength. The microstructural study of the fabricated samples has revealed the good lamination of carbon fiber in epoxy matrix and the uniform dispersion nanoparticles provide a reduction of wettability. Dielectric parameter studies indicate an increase in permittivity and dielectric loss with the addition of zirconia nanoparticles. The shielding effectiveness (SE) shows as high as 25 dB when the electric field is parallel with the carbon fiber orientation. The addition of zirconia nanoparticles to the carbon fiber reinforced epoxy composite have enhanced the ability of microwave absorption shielding. Mechanical properties of the epoxy carbon fiber nano zirconia composites show an improvement in storage modules, activation energy, and impact resistance. It is realized that 3 wt zirconia added epoxy carbon fiber composite shows high shielding effectiveness with good mechanical properties.
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