Polymer/2D material nanocomposite manufacturing beyond laboratory frontiers

Polymer nanocomposites based on 2D materials as fillers are the target in the industrial sector, but the ability to manufacture them on a large scale is very limited, and there is a lack of tools to scale up the manufacturing process of these nanocomposites. Here, for the first time, a systematic and fundamental study showing how 2D materials are inserted into the polymeric matrix in order to obtain nanocomposites using conventional and industrially scalable polymer processing machines leading to large-scale manufacturing are described. Two new strategies were used to insert pre-exfoliated 2D material into the polymer matrix, liquid-phase feeder, and solid-solid deposition. Characterizations were beyond micro and nanoscale, allowing the evaluation of the morphology for millimeter samples size. The methodologies described here are extendable to all thermoplastic polymers and 2D materials providing nanocomposites with suitable morphology to obtain singular properties and also triggering the start of the manufacturing process on a large scale.