Using a modified oxidative polymerization, the nano-fibrous polyaniline with 200 nm diameter and several micrometer lengths was synthesized on a large scale and then was applied as a new electrotheological (ER) fluid. Compared to conventional granular polyaniline ER fluid, the nano-fibrous polyaniline ER fluid exhibited distinctly improved suspended stability. Under electric fields, the nano-fibrous PANI ER fluid also exhibited larger ER effect. Its shear stresses are about 1.2-1.5 times as high as those of the granular PANI ER fluid. At the same time, the shear stress of nano-fibrous PANI ER fluid could maintain a stable level and even an increase for the wide shear rate regions from 0.1 s(-1) to 1000 s(-1) under various electric fields. In addition, the dynamic experiment showed that the shear modulus of nano-fibrous polyaniline ER fluid under electric field was higher than that of the granular polyaniline fluid, which also confirmed the larger ER effect. (c) 2008 Elsevier Ltd. All rights reserved.