This work describes an empirical study of in situ interfacial dynamic inverse emulsion polymerization process under sonication of aniline in the presence of nine different types of carbon nanotubes (CNT) in toluene. The polymerization method described in this work is simple and very fast (5 min) compared to the other literature reports (312 h). During polymerization, CNT are coated with polyaniline (PANI) forming a core-shell structure of nanowires as evidenced by transmission electron microscopy (TEM) and high-resolution scanning microscopy (HRSEM). HRSEM images and surface resistivity imply that PANI coating of CNT leads to a remarkable improvement in separation and dispersion of CNT in toluene, which otherwise would have rapidly coagulate and settle. Two of the nine different CNT studied have shown the lowest surface resistivities. Films of uniform thickness were successfully produced (HRSEM of cross-sections). The effect of film thickness on conductivity and optical properties is reported in the work. (c) 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013