AbstractFor certain commercial applications of polypyrrole (PPy), an enhancement of the electrical conductivity of the material is the key to industrial success. In this paper it will be shown that raw PPy with high conductivity (>150 S/cm) can be obtained in very good yield (>90%) by appropriate selection of both bi‐functional additives and reaction conditions which increase the oxidative polymerization rate of pyrrole. The presence of new active centers for the polymerization is demonstrated by UV measurements. In addition, raw PPy synthesized according to the improved method of synthesis shows good stability of the conductivity upon aging at high temperature (150°C) in air. Finally, new PPy dispersions are reported with an average particle size of 67 nm obtained by sonochemical synthesis that can be incorporated into conventional plastic paints for direct metallization of plastics. The conductivity of the new metallization paint developed was 0.4 S/cm with a PPy content of 10 wt%. Copyright © 2006 John Wiley & Sons, Ltd.