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
Novel graphene-enhanced spray coating enables efficient structural health monitoring in demanding environments
Researchers from China's Northeastern University, Shenyang Jusheng New Material Technology, Key Laboratory of Medical Image Computing, Shenyang Aerospace University and Australia's University of New South Wales have developed a polyurea-based nanocomposite spray sensing coating reinforced with covalently functionalized graphene nanoplatelets, offering a scalable solution for structural health monitoring in demanding environments.
Preparation and Main Properties of Graphene NanoPlatelet-functionalized Polyurea Coatings.
Structural health monitoring (SHM) in harsh and complex conditions remains challenging, as conventional sensors often lack conformability, mechanical durability, and long-term stability. In their recent study, the team outlines a new approach - a spray-applied polyurea nanocomposite sensing coating that integrates functionalized graphene nanoplatelets to combine robust mechanical performance with reliable, real-time damage and strain monitoring for infrastructure and automotive structures.
Graphene Composites announces milestone verification for its GC Patrol Shield ballistic shield
Graphene Composites USA (GC USA) has announced that its ultralight GC Patrol Shield® has become "the first and only rifle-rated ballistic shield to pass and receive third-party verification for rifle and shotgun rounds under the ASTM E3347-25 standard (Standard Specification for Ballistic-Resistant Shields Used by Law Enforcement Officers)".
Third-Party verified edge-shot protection and real-world durability at half the weight of conventional shields could have great potential for Law Enforcement safety.
Researchers develop a solvent-free, high-yield route to dispersible, nitrogen-doped graphene nanoplatelets
Researchers from Monash University and the University of Melbourne have developed a solvent-free, one-pot mechanochemical process that produces nitrogen-doped graphene nanoplatelets (N-GNPs) using glycine, a naturally occurring amino acid, as the nitrogen source. This process combines graphite, glycine, and potassium hydroxide in a planetary ball mill, where glycine enables simultaneous exfoliation and nitrogen incorporation at ambient temperature and pressure, requiring no harsh post-treatment.
This addresses known challenges standing before the successful development of processable, high-performance graphene-based materials. Traditional methods for nitrogen doping - such as high-temperature chemical vapor deposition or toxic wet-chemical reduction - often compromise environmental safety or electrical performance. The new mechanochemical route achieves both: high yield (∼80%) and strong electrical conductivity (roughly 30% that of pristine graphite) paired with long-term colloidal stability across diverse solvents.
Kivoro and Graphite India Limited enter exclusive partnership to commercialize graphene-based heat transfer additives in India
Graphite India Limited (“GIL”), one of India’s oldest and largest graphite materials companies, and Kivoro, a corporate spin-off of Graphenea and an innovator in graphene-based industrial additives, signed an Exclusive Distribution and Commercial Partnership Agreement to bring Kivoro’s graphene-based Heat Transfer Additive (HTA) technology to the Indian corrugated paperboard industry.
Under the agreement, GIL becomes the exclusive distributor of Kivoro’s Heat Transfer Additive across the Republic of India, focusing on deployment within the corrugated paperboard sector - a fast-growing, efficiency-driven industry where thermal performance improvements can significantly reduce energy consumption and costs.
Perpetuus Advanced Materials suggests graphene-based alternative to 6PPD in tires.
Perpetuus Advanced Materials has introduced an amine functionalized graphene material as a potential replacement for 6PPD (6-para-phenylene-diamine) antioxidants in tires. Using plasma-functionalized graphene nanoplatelets (GNPs), Perpetuus claims the masterbatches can entirely replace 6PPD in rubber formulations, thereby preventing the formation of harmful 6PPDQ by-products.
The masterbatch covers over 90% of the dry-mix ingredients used in tire production, replacing several process oils and additives, improving workplace air quality while keeping mixing simple, said the UK company.
NanoXplore announces supply agreement with Club Car at newly commissioned facility
NanoXplore has announced it has entered into an exclusive, long-term supply agreement with Club Car, a leading name in the recreational products industry.
This partnership will support the production of graphene-enhanced, high-performance solutions. The addition of Club Car to NanoXplore's customer portfolio marks a milestone in the Company’s diversification strategy, the Company stated, expanding its reach and revenue opportunities beyond its traditional focus in the transportation sector.
First Graphene announces first industrial-scale graphene-enhanced TPU shipment
First Graphene has completed its first industrial-scale supply of its graphene-enhanced PureGRAPH 10 masterbatch for thermoplastic polyurethane (TPU) applications. The shipment included 500 kg and is destined for integration into safety-work boot soles by Southeast Asian manufacturer PT Alasmas Berkat Utama, in collaboration with compounder Duromer.
On 1 July 2025, the company disclosed two orders totaling approximately AUD 165,000 (around USD 110,000) of PureGRAPH product, including the TPU masterbatch for high-wear applications, and noted that volumes will begin to feed into FY26. According to the recent announcement, the masterbatch will help extend polymer durability in harsh operating conditions and integrate into existing thermoplastic production lines without requiring processing changes.
Multilayer graphene tape delivers efficient cooling and electrical insulation in compact devices
Researchers from Shanghai Jiao Tong University and Shanghai Electric Power Generation Equipment have developed a multilayer graphene-based thermally conductive and electrically insulating tape (MTCEIT) that achieves a combination of lateral heat spreading capability and dielectric integrity for compact, high-power electronic systems.
The continuous miniaturization of integrated devices, accompanied by exponentially increasing power densities, imposes stringent requirements on thermal interface materials (TIMs) that must efficiently dissipate heat while providing strong electrical insulation within submillimeter thickness constraints. Conventional polymer composites and ceramic-filled films struggle to meet these competing demands, typically exhibiting in-plane thermal conductivities below 70 W m⁻¹ K⁻¹ once their thickness exceeds 200 µm. To overcome this limitation, the MTCEIT integrates graphene paper - a stacked and compressed assembly of two-dimensional graphene sheets - as a high-efficiency lateral heat spreading layer.
UK’s Perpetuus Advanced Materials launches joint venture for graphene-enhanced tires with India's Asiatic Rubber
According to reports, Perpetuus Advanced Materials, following the successful launch of its sustainable graphene-enhanced natural rubber masterbatch, had announced a joint venture with Asiatic Rubber.
This partnership marks a milestone in the commercial deployment of its advanced elastomer technologies across India and Asia. The new venture includes a comprehensive upgrade of Asiatic’s existing manufacturing facility to produce graphene, natural rubber carbon black masterbatch. This material is currently under evaluation by several of India’s leading multinational tire producers.
HydroGraph and SEADAR Technologies to jointly advance graphene-enhanced maritime applications
Graphene producer HydroGraph and SEADAR Technologies, developers of subsea radar systems, have signed a letter of intent to integrate HydroGraph’s graphene materials and coating technologies into SEADAR’s current and future undersea products.
The letter of intent describes how HydroGraph and SEADAR will collaborate to explore technical synergies that enhance performance for SEADAR products, positioning both companies to expand into new markets, such as maritime defense and offshore energy.
