biostudies-literatureUnknown17(1)Tian KThe fabrication of high-performance functional polymer composites requires delicate balance between functionalities, filler content and overall performance, and preparation route is urgently needed. Guided by Simmons theory, a PDMS-based stretchable conductor with metal-level conductivity is realized through a strategy by combining silver nanoparticle in-situ formation, optimized barrier height and volume excluding effect. Firstly, a universal matrix-independent etching-reduction method generates uniform Ag nanoparticles (~ 9.7 nm), shortening tunneling distances. Then, tunneling barrier height is minimized to 0.06 eV by aligning energy levels of surface-treated silver nanoflakes and PDMS, reducing electron scattering. Finally, silver-plated PDMS microspheres act as volume-excluding phase,Nature communications728https://www.ebi.ac.uk/biostudies/studies/S-EPMC12820149biostudies-literatureDesigning functional filler networks via in situ silver nanoparticles through barrier tuning and volume exclusion.PMC12820149Wen YTian KFu QJing JWen JWen MLi QCheng MZhang LDeng HfalseDesigning functional filler networks via in situ silver nanoparticles through barrier tuning and volume exclusion.The fabrication of high-performance functional polymer composites requires delicate balance between functionalities, filler content and overall performance, and preparation route is urgently needed. Guided by Simmons theory, a PDMS-based stretchable conductor with metal-level conductivity is realized through a strategy by combining silver nanoparticle in-situ formation, optimized barrier height and volume excluding effect. Firstly, a universal matrix-independent etching-reduction method generates uniform Ag nanoparticles (~ 9.7 nm), shortening tunneling distances. Then, tunneling barrier height is minimized to 0.06 eV by aligning energy levels of surface-treated silver nanoflakes and PDMS, reducing electron scattering. Finally, silver-plated PDMS microspheres act as volume-excluding phase,2025-01-01T00:00:00Z2025 Dec2026-06-06T17:54:42.487Z2026-06-04T03:08:16.012ZS-EPMC128201494138743910.1038/s41467-025-67461-6