The large-scale assembly of asymmetric colloidal particles is used in creating high-performance fibres. A similar concept is extended to the manufacturing of thin films of self-assembled two-dimensional crystal-type materials with enhanced and tunable properties. Here we present a spray-coating method to manufacture thin, flexible and transparent epoxy films containing zirconium phosphate nanoplatelets self-assembled into a lamellar arrangement aligned parallel to the substrate. The self-assembled mesophase of zirconium phosphate nanoplatelets is stabilized by epoxy pre-polymer and exhibits rheology favourable towards large-scale manufacturing. The thermally cured film forms a mechanically robust coating and shows excellent gas barrier properties at both low-and high humidity levels as a result of the highly aligned and overlapping arrangement of nanoplatelets. This work shows that the large-scale ordering of high aspect ratio nanoplatelets is easier to achieve than previously thought and may have implications in the technological applications for similar materials.

A direct colloidal self-assembly approach was utilized to prepare photonic crystals based on exfoliated graphene oxide (GO) in aqueous solution. The GO sheets form ordered photonic structure spontaneously without the need for multiple processing steps. The wavelength of light reflected by the GO photonic crystal dispersion can be controlled over the entire visible light spectrum simply by varying the GO concentration. The aspect ratio of the GO sheets and mediation of the intersheet forces are found to be the key factors influencing the stability of photonic crystal formation. The usefulness and limitations of the GO photonic crystals prepared in this study are discussed.

Morphology and fracture mechanisms in two nanoclay‐filled epoxy systems were investigated using both microscopy and spectroscopy tools. Clay exfoliation was achieved using a series of sample preparation steps, and confirmed using wide angle X‐ray diffraction (XRD) and transmission electron microscopy (TEM) techniques. Significant improvement in modulus was obtained when clay exfoliation was achieved. Incorporation of core‐shell rubber (CSR) in both caly‐filled epoxy systems leads to greatly enhanced fracture toughness. Optical microscopy and TEM observations of the CSR‐modified nanocomposites suggest that CSR cavitation. shear yielding of the matrix, clay layer delamination. CSR bridging, crack bifurcation. and crack deflection are among the operative toughening mechanisms observed, depending on the nature of the epoxy matrix utilized.

Epoxy nanocomposite coatings containing self-assembled α-zirconium phosphate nanoplatelets (ZrP) in smectic order were successfully prepared by spray-coating on an aluminum substrate using a simple, energy-efficient fabrication process that is suitable for industrial practices.