Graphene composites: introduction and market status
What are composite materials?
Composite materials (also referred to as composition materials, or simply composites) are materials formed by combining two or more materials with different properties to produce an end material with unique characteristics. These materials do not blend or dissolve together but remain distinct within the final composite structure. Composite materials can be made to be stronger, lighter or more durable than traditional materials due to properties they gain from combining their different components.
Most composites are made up of two materials - the matrix (or binder) surrounds a cluster of fibers or fragments of a stronger material (reinforcement). A common example of this structure is fiberglass, which was developed in the 1940’s to be the first modern composite and is still in widespread use. In fiberglass, fine fibers of glass, which are woven into a cloth of sorts, act as the reinforcement in a plastic or resin matrix.
While composite materials are not a new concept (for example, mud bricks, made from dried mud embedded with straw pieces, have been around for thousands of years), recent technologies have brought many new and exciting composites to existence. By careful selection of matrix and reinforcement (as well as the best manufacturing process to bring them together) it is possible to create significantly superior materials, with tailored properties for specific needs. Typical composite materials include composite building materials like cement and concrete, different metal composites, plastic composites and ceramic composites.
How are composite materials made?
The three main factors that help mold the end composite material are the matrix, reinforcement and manufacturing process. As matrix, many composites use resins, which are thermosetting or thermosoftening plastics (hence the name ‘reinforced plastics’ often given to them). These are polymers that hold the reinforcement together and help determine the physical properties of the end composite.
Thermosetting plastics begin as liquid but then harden with heat. They do not return to liquid state and so they are durable, even in extreme exposure to chemicals and wear. Thermosoftening plastics are hard at low temperatures and but soften with heat. They are less commonly used but possess interesting advantages like long shelf life of raw material and capacity for recycling. There are other matrix materials such as ceramics, carbon and metals that are used for specific purposes.
Reinforcement materials grow more varied with time and technology, but the most commonly used ones are still glass fibers. Advanced composites tend to favor carbon fibers as reinforcement, which are much stronger than glass fibers, but are also more expensive. Carbon fiber composites are strong and light, and are used in aircraft structures and sports gear (golf clubs and various rackets). They are also increasingly used to replace metals that replace human bones. Some polymers make good reinforcement materials, and help make composites that are strong and light.
The manufacturing process usually involves a mould, in which the reinforcement is first placed and then the semi-liquid matrix is sprayed or poured in to form the object. Moulding processes are traditionally done by hand, though machine processing is becoming more common. One of the new methods is called ‘pultrusion’ and is ideal for making products that are straight and have a constant cross section, like different kinds of beams. Products that of thin or complex shape (like curved panels) are built up by applying sheets of woven fiber reinforcement, saturated with matrix material, over a mould. Advanced composites (like those which are used in aircraft) are usually made from a honeycomb of plastic held between two sheets of carbon-fiber reinforced composite material, which results in high strength, low weight and bending stiffness.
Where can composites be found?
Composite materials have many obvious advantages, as they can be made to be lightweight, strong, corrosion and heat resistant, flexible, transparent and more according to specific needs. Composites are already used in many industries, like boats, aerospace, sports equipment (golf shafts, tennis rackets, surfboards, hockey sticks and more), Automotive components, wind turbine blades, body armour, building materials, bridges, medical utilities and others. Composite materials’ merits and potential assures ample research in the field which is hoped to bring future developments and implementations in additional markets.
Modern aviation is a specific example of an industry with complex needs and requirements, which benefits greatly from composite materials’ advantages. This industry raises demands of light and strong materials, that are also durable to heat and corrosion. It is no surprise, then, that many aircraft have wing and tail sections, as well as propellers and rotor blades made of composites, along with much of the internal structure.
What is graphene?
Graphene is a two-dimensional matrix of carbon atoms, arranged in a honeycomb lattice. A single square-meter sheet of graphene would weigh just 0.0077 grams but could support up to four kilograms. That means it is thin and lightweight but also incredibly strong. It also has a large surface area, great heat and electricity conductivity and a variety of additional incredible traits. This is probably why scientists and researchers call it “a miracle material†and predict it will revolutionize just about every industry known to man.
Graphene and composite materials
As was stated before, graphene has a myriad of unprecedented attributes, any number of which could potentially be used to make extraordinary composites. The presence of graphene can enhance the conductivity and strength of bulk materials and help create composites with superior qualities. Graphene can also be added to metals, polymers and ceramics to create composites that are conductive and resistant to heat and pressure.
Graphene composites have many potential applications, with much research going on to create unique and innovative materials. The applications seem endless, as one graphene-polymer proves to be light, flexible and an excellent electrical conductor, while another dioxide-graphene composite was found to be of interesting photocatalytic efficiencies, with many other possible coupling of materials to someday make all kinds of composites. The potential of graphene composites includes medical implants, engineering materials for aerospace and renewables and much more.
Further reading
- Graphene Supercapacitors
- Introduction to graphene
- Graphene company database
- How to invest in the graphene revolution
- The Graphene Handbook, our very own guide to the graphene market
Researchers develop 3D-printed graphene composites for efficient ice control applications
Researchers from Hefei University and Chinese Academy of Sciences (CAS) have developed a novel 3D-printed graphene/polymer double-layer composite featuring high anisotropic thermal conductivity that offers improved photothermal and electrothermal performance for advanced ice control applications.
Graphene is known for its outstanding thermal and electrical conductivity, particularly its strong anisotropy—high in-plane conductivity and much lower through-plane conductivity. To capitalize on this property, the researchers used dual-nozzle fused deposition modeling (FDM) 3D printing to directionally align graphene within a thermoplastic polyurethane (TPU) matrix. The resulting double-layer composite, consisting of graphene-enhanced TPU (G-TPU) and neat TPU (N-TPU), achieved an in-plane thermal conductivity of 4.54 W/(m·K), with an anisotropic ratio of about 8.
New rGO/layered double hydroxide composites for improved lithium-ion batteries
Researchers from Korea's Kyungpook National University and Dongguk University recently addressed common challenges presented by current lithium-ion batteries, by engineering materials at the nanoscale. Their work focuses on a novel hybrid material designed to maximize the synergistic effects of its components.
Image credit: Chemical Engineering Journal
The composite is a hierarchical heterostructure that combines reduced graphene oxide (rGO) with nickel-iron layered double hydroxides (NiFe-LDH). This unique composite leverages the properties of its components: rGO provides a conductive network for electron transport, and the nickel-iron-oxide components enable fast charge storage through a pseudocapacitive mechanism. The key to this innovative design is the abundance of grain boundaries, which facilitate efficient charge storage.
New method uses bacteria-enhanced graphene oxide nanoparticles for cancer photothermo-chemo-immunotherapy
Modern cancer treatments have evolved beyond traditional chemotherapy to include targeted approaches such as immunotherapy, radiation therapy, and photothermal therapy. Graphene oxide (GO) has emerged as a promising material for both drug delivery and thermal-based tumor destruction. However, its clinical application remains limited due to challenges in dispersibility and large-scale production.
To overcome these limitations, Professor Eijiro Miyako and his research team from the Japan Advanced Institute of Science and Technology (JAIST) have developed a novel GO nanocomposite enhanced with bacterial components. The study highlights how bacterial properties improve GO's effectiveness in cancer therapy. Certain bacteria naturally stimulate immune responses and enhance dispersibility of GO due to their amphiphilic cellular components.
Transteel and Tata Steel unveil graphene jute-cotton furniture fabrics
Transteel has teamed up with Tata Steel to introduce graphene-enhanced jute and cotton fabrics to India’s commercial furniture landscape. The advanced upholstery material, designed to boost durability and wellness, will aim to support a circular economy model and significantly reduce reliance on plastics.
The collaboration showcases Transteel’s new bio chairs collection, in combination with Tata Steel’s advanced graphene-treated natural fibers. Transteel highlights its vision of eco-conscious design that doesn’t compromise on performance.
Levidian and Graphmatech partner to advance graphene applications in the clean hydrogen field
British climate tech startup Levidian has announced a strategic collaboration with Swedish deep-tech startup Graphmatech to co-develop new graphene-based polymer solutions for the hydrogen sector and other high-growth industries.
The companies aim to accelerate the market adoption of graphene, bringing together Levidian's graphene production capability with Graphmatech's modular dispersion technology to manufacture high-performance polymer-graphene composites for industrial applications. Use cases for these composites include pipelines and hydrogen pressure vessels where graphene has been shown to reduce hydrogen gas leakage by up to 83%.
Glenntex secured funding to promote graphene-enhanced 'green' packaging materials
Paulig’s venture arm, PINC, is investing in Glenntex, a Sweden-based startup that has developed a method to functionalize graphene to reduce the need for virgin plastic in packaging by up to 30%. Paulig is an international food and beverage company and PINC is its venture arm for investments in early-stage startups in and around the future of food.
The European Union is driving circularity efforts, with the implementation of ‘The Packaging and Packaging Waste Regulation’ (PPWR), aiming to ensure that all packaging is reusable or recyclable by 2030. Innovation and packaging design is key for the industry’s ability to meet the sustainability targets for 2030 and beyond.
Versarien expands agreement with Montana Química
Versarien has announced, further to the previously announced manufacturing license agreement, know-how license and technical assistance agreement entered into with Montana Química, that it has now signed a two-year supply agreement to provide some of the Company's proprietary graphene and related material dispersions and formulations (Graphinks™) to Montana (the "Supply Agreement").
Montana is a Brazilian headquartered multinational business focused on the production and sale of paints, wood preservatives and other wood finishing products including paints, stains and varnishes. Versarien understands it is Montana's intention to utilize the Company's Graphinks™ in application areas such as construction, composites, coatings and lubricants.
Nova Graphene signs MOU to co-develop graphene-enhanced polymer sheeting and greases
Canada-based Nova Graphene has signed a memorandum of understanding to co-develop graphene-enhanced polymer sheeting and greases in Australia.
The value of the deal was not announced, but it was finalized during a Team Canada trade mission to Australia. Nova Graphene's CEO, Paul Beasant, is part of the mission, and a news release describes the MOU as “a significant step toward advancing the development and commercialization of cutting-edge graphene applications in the Indo-Pacific region.”
Perpetuus launches graphene-enhanced masterbatch for sustainable tire manufacturing
Perpetuus Advanced Materials has announced its first nano-engineered graphene-enhanced masterbatch compounds, tailored specifically for commercial, passenger, and industrial tire manufacturing. The initial release will soon expand to include polymer and elastomer masterbatches for use in industries such as hoses, seals, gaskets, V-belts, and conveyor belts.
By utilizing its environmentally friendly plasma treatment process, Perpetuus incorporates its advanced graphene into the masterbatch. This innovation is now available in industrial quantities, enabling tire manufacturers to integrate this breakthrough material into their existing production workflows.
GIM strikes deal with Saudi Arabia for commercial production of carbon fiber enriched with graphene
UK-based Graphene Innovations Manchester (GIM) has entered into a deal for the commercial production of carbon fiber enriched with graphene in Saudi Arabia. Graphene Innovations Manchester has agreed to construct a factory in the Gulf state to manufacture the material for use in the kingdom's plans to build futurist eco-cities in the desert.
The factory will be built in Saudi Arabia with the backing of investors. Image from: BBC
Reports suggest that about £250 million could be invested in building a research and innovation hub in Greater Manchester as part of the deal and more than 1,000 jobs could be created.
