We demonstrate that functionalized pyrene derivatives effectively stabilize single- and few-layer graphene flakes in aqueous dispersions. The graphene/stabilizer yield obtained by this method is exceptionally high relative to conventional nanomaterial stabilizers such as surfactants or polymers. The mechanism of stabilization by pyrene derivatives is investigated by studying the effects of various parameters on dispersed graphene concentration and stability; these parameters include stabilizer concentration, initial graphite concentration, solution pH, and type and number of functional groups and counterions. The effectiveness of the pyrene derivatives is pH-tunable, as measured by zeta potential, and is also a function of the number of functional groups, the electronegativity of the functional group, the counterion, the relative polarity between stabilizer and solvent, and the distance from the functional group to the basal plane. Even if the dispersion is destabilized by extreme pH or lyophilization, the graphene does not aggregate because the stabilizer remains adsorbed on the surface. These dispersions also show promise for applications in graphene/polymer nanocomposites (examined in this paper), organic solar cells, conductive films, and inkjet-printed electronic devices.

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Recent developments in the exfoliation, dispersion, and processing of pristine graphene (i.e., non-oxidized graphene) are described. General metrics are outlined that can be used to assess the quality and processability of various "graphene" products, as well as metrics that determine the potential for industrial scale-up. The pristine graphene production process is categorized from a chemical engineering point of view with three key steps: i) pretreatment, ii) exfoliation, and iii) separation. How pristine graphene colloidal stability is distinct from the exfoliation step and is dependent upon graphene interactions with solvents and dispersants are extensively reviewed. Finally, the challenges and opportunities of using pristine graphene as nanofillers in polymer composites, as well as as building blocks for macrostructure assemblies are summarized in the context of large-scale production.

For the first time, pristine graphene can be controllably crumpled and unfolded. The mechanism for graphene is radically different than that observed for graphene oxide; a multifaced crumpled, dimpled particle morphology is seen for pristine graphene in contrast to the wrinkled, compressed surface of graphene oxide particles, showing that surface chemistry dictates nanosheet interactions during the crumpling process. The process demonstrated here utilizes a spray-drying technique to produce droplets of aqueous graphene dispersions and induce crumpling through rapid droplet evaporation. For the first time, the gradual dimensional transition of 2D graphene nanosheets to a 3D crumpled morphology in droplets is directly observed; this is imaged by a novel sample collection device inside the spray dryer itself. The degree of folding can be tailored by altering the capillary forces on the dispersed sheets during evaporation. It is also shown that the morphology of redispersed crumpled graphene powder can be controlled by solvent selection. This process is scalable, with the ability to rapidly process graphene dispersions into powders suitable for a variety of engineering applications.