PANI/PMMA composite was synthesized by emulsion polymerization pathway and the composite thin film was obtained by vacuum evaporation. The effect of vapour chopping and varying PMMA concentration was also studied. The FTIR spectra showed that the PANI/PMMA composite thin film deposited as a short chain oligomers. Increase in transmittance and decrease in refractive index was obtained with increasing concentration of PMMA, which further increased the adhesion and decreased intrinsic stress. The vapour chopping improved its optical as well as mechanical properties and produced smoother surface morphology. Increase of PMMA made the film more amorphous and does not change its band gap. (c) 2007 Elsevier B.V. All rights reserved.