| Abstract Scope |
We developed a fabrication workflow for advanced, flexible composites derived from vertically aligned single-walled carbon nanotube (SWCNT) “forests” based on a series of wafer-scale chemical vapor deposition (CVD) techniques. Our initial SWCNT synthesis co-optimized growth of small diameters (mean < 2 nm) and high densities (> 1012 cm-2) uniformly across large areas (6-in. wafers) to access new territory in this 3D parameter space. Mass conversion rates from low-pressure acetylene to solid SWCNT product were high (up to 65%) and remarkably invariant for different metal nano-catalyst compositions and densities, far exceeding typical benchtop reactors. Subsequent vapor-phase polymer chemistry enabled functionalization and infiltration within nanoscale voids between SWCNTs without destroying the unique aligned morphology. Routine manufacture of these high-quality materials at a practical scale unlocked a portfolio of high-performance applications, including optical metamaterials, twist-spun yarns, and nanofluidic devices for molecular separation, energy storage, and sensing. |