Films of blended poly(acrylonitrile-butadiene-styrene) (ABS) and polyaniline (PANT) were produced by codissolving both components in a common organic solvent, which was then evaporated. The influence of the preparation conditions on the properties of the blends was analyzed by factorial design. The factors evaluated were the PANT content in the blend, the in-cresol to chloroform solvent ratio, the dopant used (dodecylbenzenesulfonic acid (DBSA) or camphor sulfonic acid) and its concentration, and the acrylonitrile content in the ABS. The responses analyzed were the flexibility and electrical conductivity of the blends. The results showed that the PANT content in the blend and the acrylonitrile content in the ABS were the major factors influencing both of the assessed responses. The dopant affected only the conductivity, DBSA being preferred for the development of more conductive PANI/ABS blends. The solvent ratio did not have any influence, owing to the uniform expanded coil conformation expected for PANT molecules at the studios ratios. After the best conditions had been established, a percolation threshold study was performed that pointed to a low threshold of 3 wt % PANT necessary in the blend, giving a flexible blend with a conductivity of 3 S/cm. (C) 2009 Wiley Periodicals, Inc. J Appl Polym Sci 116: 825-831, 2010