Composites made of polyethersulfone (PES) reinforced with exfoliated graphite nanoplatelets are fabricated by melt mixing, polymer solution, and coating. Coating is an efficient compounding method emphasized in this research, where expanded graphite (EG) and PES powder are premixed in isopropyl alcohol using sonication to disperse the EG by coating individual PES powder particles. The microstructure and property of EG/PES composites were investigated by X-ray diffraction, scanning electron microscope, thermal gravimetric analysis, differential scanning calorimetric, and electronic tensile tester. The electrical conductivity was confirmed using electrochemical tester. It is found that the coating method is more effective than the polymer solution and directly melt mixing methods widely used, in terms of increasing the electrical conductivity and lowering the percolation threshold of thermoplastic composites, and enhancing the probability that the large platelet morphology of EG can be preserved in the final composite. The research reported here provides an understanding on how the compounding method used during the fabrication of composites is important to achieving the optimal mechanical properties, thermal properties, electrical conductivity, and percolation threshold. This method should have wide applicability to all thermoplastic matrix composite systems. (C) 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012