Roll to roll

US-based CVD graphene developer General Graphene Corporation (GGC) has launched its new Gen3.0 CVD graphene production line. This 20-meters long roll-to-roll based system can produce single- and multi-layer graphene materials on copper films up to 400 mm wide.

GGC says that with the new line, its manufacturing capacity exceeds 100,000 m²/year. The company is now able to supply affordable and highly consistent CVD graphene in industrial volumes.

Korea-based Charmgraphene has started to mass produce CVD graphene, using its proprietary roll-to-roll process.

CharmGraphene's graphene on copper and heating element

CharmGraphene's R2R production system can produce 2 meters of CVD graphene per minute (maximum width 300 mm). According to CharmGraphene, its current CVD graphene capacity is about 8,000 sqm per month. The company says it uses use 6 um thick copper foil which reduces copper foil etching time dramatically compare to 35 um thickness copper foil used by other companies.

Researchers at MIT have developed a new roll-to-roll production process for large sheets of high-quality graphene, which the team says could lead to ultra-lightweight, flexible solar cells, and to new classes of light-emitting devices and other thin-film electronics.

The new manufacturing process, which the team says should be relatively easy to scale up for industrial production, involves an intermediate buffer layer of material that is key to the technique’s success. The buffer allows the ultrathin graphene sheet, less than a nanometer (billionth of a meter) thick, to be easily lifted off from its substrate, allowing for rapid roll-to-roll manufacturing.

According to our information, LG Electronics is aiming to start supplying CVD graphene materials worldwide soon, with an aim to accelerate the adoption of CVD graphene in various applications. LG is collaborating with research groups to identify new applications for graphene sheets.

LG Electronics developed its own roll-to-roll production process in addition to a specific quality control system for its graphene. LG says that its inspection system can manage uniformity deviations in crystal size, defects and electrical properties in its graphene to within 10%.

Scientists from RMIT University in Melbourne, Australia, have developed a cost-efficient and scalable method for rapidly fabricating textiles that are embedded with energy storage devices. The team reports that in just three minutes, the method can produce a 10x10cm smart textile patch that's waterproof, stretchable and readily integrated with energy technologies like graphene supercapacitors, laser printed directly onto the textiles.

As a proof-of-concept, the researchers connected the supercapacitor with a solar cell, delivering an efficient, washable and self-powering smart fabric that overcomes the key drawbacks of existing e-textile energy storage technologies.

AIXTRON recently showcased two of its systems, which enable cost effective graphene production for a myriad of applications such as consumer electronics, sensors and photonic applications.

AIXTRON's new 'Neutron' roll to roll system for the production of graphene. Credit: AIXTRON

Graphene Flagship partner AIXTRON introduced results from two of its systems that enable the large-scale production of graphene through chemical vapor deposition (CVD). The Neutron is a roll-to-roll system capable of depositing large areas of graphene on metal foils under ambient conditions; and the CCS 2D system enables wafer-scale production of graphene on insulating wafers, a breakthrough that could speed up the development of new graphene electronics.

A China-based company named Shenzhen Danbond Technology announced that it had begun mass production trials of a self-developed graphene product.

The product seems to be a highly-conductive film that can be used in electric vehicle batteries, to dissipate heat in electronic devices and in solar power generation and flexible screens, according to the company. It reportedly plans to begin mass production early next year.

Versarien, the advanced materials engineering group, has provided an update on its activities in relation to graphene-enhanced power storage devices like batteries and supercapacitors. The primary goal of incorporating graphene into these devices, Versarien says, is to significantly increase power storage capacity and reduce charging times.

Versarien has been working with WMG (Warwick Manufacturing Group) and their partner companies and scientists at the universities of Warwick and Cambridge to collaborate on the production of power storage devices such as batteries and supercapacitors using Versarien's proprietary Nanene graphene nano platelets. Significant advances have been made through incorporating the Company's high quality graphene into these devices and the Company looks forward to commercial products becoming available in due course.

Researchers at MIT have developed a method that might enable the production of long rolls of high-quality graphene. The continuous manufacturing process can reportedly produce five centimeters of high-quality graphene per minute. The longest run was nearly four hours, and it generated around 10 meters of continuous graphene.

MIT is referring to the development as the first demonstration of an industrial, scalable method for manufacturing high-quality graphene that is tailored for use in membranes that filter a variety of molecules. These membranes could be used in biological separation or desalination, for example. The researchers drew from the common industrial roll-to-roll approach blended with chemical vapor deposition, a common graphene-fabrication technique.

A team led by the Department of Energy’s Oak Ridge National Laboratory, that also included scientists from University of Tennessee, Rice University and New Mexico State University, has developed a new method to produce large, monolayer single-crystal-like graphene films more than a foot long. The novel technique may open new opportunities for producing high-quality graphene of unlimited size and in a way that is suitable for roll-to-roll production.

The ORNL team used a CVD method — but with a twist. They explained in this work how localized control of the CVD process allows evolutionary, or self-selecting, growth under optimal conditions, yielding a large, single-crystal-like sheet of graphene. Large single crystals are more mechanically robust and may have higher conductivity, ORNL lead coauthor Ivan Vlassiouk said. This is because weaknesses arising from interconnections between individual domains in polycrystalline graphene are eliminated. Our method could be the key not only to improving large-scale production of single-crystal graphene but to other 2D materials as well, which is necessary for their large-scale applications, he added.