Decades of extensive research have matured the development of carbon nanotubes (CNTs). Still, the properties of macroscale assemblages, such as sheets of carbon nanotubes, are not good enough to satisfy many applications. This paper gives an overview of different approaches to synthesize CNTs and then focuses on the floating catalyst method to form CNT sheets. A method is also described in this paper to modify the properties of macroscale carbon nanotube sheets produced by the floating catalyst method. The CNT sheet is modified to form a carbon nanotube hybrid (CNTH) sheet by incorporating metal, ceramic, or other types of nanoparticles into the high-temperature synthesis process to improve and customize the properties of the traditional nanotube sheet. This paper also discusses manufacturing obstacles and the possible commercial applications of the CNT sheet and CNTH sheet. Manufacturing problems include the difficulty of injecting dry nanoparticles uniformly, increasing the output of the process to reduce cost, and safely handling the hydrogen gas generated in the process. Applications for CNT sheet include air and water filtering, energy storage applications, and compositing CNTH sheets to produce apparel with anti-microbial properties to protect the population from infectious diseases. The paper also provides an outlook towards large scale commercialization of CNT material.

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This paper describes innovative work in the manufacturing of carbon nanotube (CNT) fabric and tape and how these materials can be used in textiles and fashion apparel. The field of CNT fabric is new and this article discusses the potential commercial impact of CNT fabric, the manufacturing barriers that currently exist, and provides suggestions to push the field towards large scale commercialization. Areas under investigation for commercialization of CNT fabric, tape and yarn include flexible heaters, filter membranes, smart textiles, electrical machines, hybrid fabric, and biomedical wire.

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Carbon nanotubes (CNTs) have extraordinary properties and are used for applications in various fields of engineering and research. Due to their unique combination of properties, such as good electrical and thermal conductivity and mechanical strength, there is an increasing demand to produce CNTs with enhanced and customized properties. CNTs are produced using different synthesis methods and have extraordinary properties individually at the nanotube scale. However, it is challenging to achieve these properties when CNTs are used to form macroscopic sheets, tapes, and yarns. To further improve the properties of macroscale forms of CNTs, various types of nanoparticles and microfibers can be integrated into the CNT materials. The nanoparticles and microfibers can be chosen to selectively enhance the properties of CNT materials at the macroscopic level. In this paper, we propose a technique to manufacture carbon hybrid materials (CHMs) by combining CNT non-woven fabric (in the form of sheets or tapes) with microfibers to form CNT-CF hybrid materials with new/improved properties. CHMs are formed by integrating or adding nanoparticles, microparticles, or fibers into the CNT sheet. The additive materials can be incorporated into the synthesis process from the inlet or the outlet of the reactor system. This paper focuses on CHMs produced using the gas phase pyrolysis method with microparticles/fibers integrated at the outlet of the reactor and continuous microfiber tapes integrated into the CNT sheet at the outlet using a tape feeding machine. After synthesis, characterizations such as microscopy and thermogravimetric analysis were used to study the morphology and composition of the CNTs, and examples for potential applications are discussed in this paper.

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The integration of carbon nanotube fabric into textiles is paving its way into smart materials and wearable applications. Potential novel applications of carbon nanotube hybrid (CNTH) materials and fabric composites span across a range of market levels from high-level PPE appropriate for military and industrial applications down to consumer products that can be used in everyday scenarios. The high-level performance properties of CNTH materials and their ability to be customized provide new possibilities for constructing fabrics with properties that are made to order. Furthermore, CNTH in combination with advanced textile compositing and construction methods allows the CNTH material to further leverage material customization aspects to meet specific requirements. The unique synthesis process for nanotube fabric allows for modification of the physical properties of the CNTH itself. The CNTH fabric combined with the customizability of standard textile composite materials and with the use of apparel design features allows for the design of materials with new combinations of physical properties. These unique properties offer high potential for developing families of smart wearable garments that can be scaled for industrial production. This article discusses the synthesis of carbon nanotube hybrid fabric, the process of hybrid fabric and textile integration, properties of the hybrid textile, and potential applications. The paper also provides an outlook towards large scale production of the hybrid textile material.

Carbon nanotube hybrid textiles (CNHT) are produced from a carbon nanotube (CNT) gas phase pyrolysis floating catalyst process with particle injection. The CNT based metal and ceramic textiles produced can be customized for different applications.Research is underway by a large group of students and faculty members working in different disciplines to further investigate injection of different types of nanoparticles in order to wet the nanotubes and to customize the properties of textiles. A brief introduction to this new material is given in this paper.