Method of Large Scale Fabrication of High CNT Content Composites with High Mechanical and Electrical Performance

Carbon nanotubes are ideal for polymer matrix composites due to their mechanical and electrical properties. However, to date, the overall properties of CNT-polymer composites have not reached their full potential due to poor dispersion and low concentrations of CNTs. Our new scalable process yields high-CNT content (60 wt%) polymer composites using a simple, three-step process:

1. A filament winding process that allows for control of CNT orientation and overall composite thickness.
2. A mechanical stretching process that has shown improved CNT alignment and overall composite properties.
3. A curing process under tension that further stretches and aligns the CNTs in the stress direction.

These improved polymer composites are ideal for defense applications and deep space exploration.