Abstract: Objects produced by conventional three-dimensional printing methods often have limited structural quality. Printing compositions to address this issue can include a solidifiable matrix and a plurality of carbon nanostructures dispersed in the solidifiable matrix. The carbon nanostructures include a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another. Three-dimensional printing methods utilizing such printing compositions can include: depositing the printing composition in a layer-by-layer deposition process, and while depositing the printing composition, applying a focused input of microwave radiation in proximity to a location where the printing composition is being deposited. The focused input of microwave radiation heats the carbon nanostructures at the location and promotes consolidation of the printing composition within an object being produced by the layer-by-layer deposition process.

Abstract: A system for synthesizing carbon nanotubes (CNT) on a fiber material includes a surface treatment system adapted to modify the surface of the fiber material to receive a barrier coating upon which carbon nanotubes are to be grown, a barrier coating application system downstream of the surface treatment system adapted to apply the barrier coating to the treated fiber material surface, and a barrier coating curing system downstream of the barrier coating application systems for partially curing the applied barrier coating to enhance reception of CNT growth catalyst nanoparticles.

Abstract: Described herein are multi-functional composite materials containing energy storage assemblies that can be significantly resistant to tension/compression stress. The energy storage assemblies can contain at least one energy storage layer that contains an insulating layer having a plurality of openings arranged in a spaced apart manner, and a plurality of energy storage devices, each energy storage device being contained within one of the openings. The energy storage devices can be electrically connected to one another. The energy storage layer can contain a support material upon which electrical connections are formed. One or more energy storage layers can be disposed between two or more stress carrying layers to form an energy storage assembly that can have significant resistance to tension/compression stress. Energy storage devices suitable for use in the energy storage assemblies can include, for example, batteries, capacitors and/or supercapacitors.

Abstract: Objects produced by conventional three-dimensional printing methods are often incompletely consolidated and are not easily repaired. Printing compositions to address this issue can include a solidifiable matrix and a microwave absorber dispersed in the solidifiable matrix. The microwave absorber can be a plurality of carbon nanostructures containing a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another. Methods for processing a three-dimensional printed object can include: providing a three-dimensional printed object formed from a printing composition containing a solidifiable matrix and a microwave absorber dispersed in the solidifiable matrix, and applying a focused input of microwave radiation to the printed object at one or more locations. Applying the microwave radiation heats the microwave absorber at the one or more locations and promotes consolidation of the printing composition within the printed object.

Abstract: A system for synthesizing carbon nanotubes (CNT) on a fiber material includes a surface treatment system adapted to modify the surface of the fiber material to receive a barrier coating upon which carbon nanotubes are to be grown, a barrier coating application system downstream of the surface treatment system adapted to apply the barrier coating to the treated fiber material surface, and a barrier coating curing system downstream of the barrier coating application systems for partially curing the applied barrier coating to enhance reception of CNT growth catalyst nanoparticles.

Abstract: Carbon nanostructures free of an adhered growth substrate can include a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another. Under applied shear, crosslinks between the carbon nanotubes in carbon nanostructures can break to form fractured carbon nanotubes that are branched and share common walls. Methods for making polymer composites from carbon nanostructures can include combining a polymer matrix and a plurality of carbon nanostructures that are free of an adhered growth substrate, and dispersing the carbon nanostructures in the polymer matrix under applied shear. The applied shear breaks crosslinks between the carbon nanotubes to form a plurality of fractured carbon nanotubes that are dispersed as individuals in the polymer matrix. Polymer composites can include a polymer matrix and a plurality of fractured carbon nanotubes dispersed as individuals in the polymer matrix.

Abstract: A composition includes a carbon nanotube (CNT)-infused metal fiber material which includes a metal fiber material of spoolable dimensions, a barrier coating conformally disposed about the metal fiber material, and carbon nanotubes (CNTs) infused to the metal fiber material. A continuous CNT infusion process includes: (a) disposing a barrier coating and a carbon nanotube (CNT)-forming catalyst on a surface of a metal fiber material of spoolable dimensions; and (b) synthesizing carbon nanotubes on the metal fiber material, thereby forming a carbon nanotube-infused metal fiber material.

Abstract: A composition includes a carbon nanotube (CNT)-infused carbon fiber material that includes a carbon fiber material of spoolable dimensions and carbon nanotubes (CNTs) infused to the carbon fiber material. The infused CNTs are uniform in length and uniform in distribution. The CNT infused carbon fiber material also includes a barrier coating conformally disposed about the carbon fiber material, while the CNTs are substantially free of the barrier coating. A continuous CNT infusion process includes: (a) functionalizing a carbon fiber material; (b) disposing a barrier coating on the functionalized carbon fiber material (c) disposing a carbon nanotube (CNT)-forming catalyst on the functionalized carbon fiber material; and (d) synthesizing carbon nanotubes, thereby forming a carbon nanotube-infused carbon fiber material.

Abstract: Carbon nanostructures free of an adhered growth substrate can include a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another. Under applied shear, crosslinks between the carbon nanotubes in carbon nanostructures can break to form fractured carbon nanotubes that are branched and share common walls. Methods for making polymer composites from carbon nanostructures can include combining a polymer matrix and a plurality of carbon nanostructures that are free of an adhered growth substrate, and dispersing the carbon nanostructures in the polymer matrix under applied shear. The applied shear breaks crosslinks between the carbon nanotubes to form a plurality of fractured carbon nanotubes that are dispersed as individuals in the polymer matrix. Polymer composites can include a polymer matrix and a plurality of fractured carbon nanotubes dispersed as individuals in the polymer matrix.

Abstract: Carbon nanostructures can be formed into polymer composites that are electrically conductive and highly reflective of microwave radiation, thereby facilitating transmission of the microwave radiation. Microwave transmission assemblies containing carbon nanostructures can include an elongate structure containing elongate opposing surfaces that extend the length of the elongate structure and that are spaced apart from one another with a channel region defined in between. The elongate opposing surfaces include a polymer composite containing a polymer matrix and a plurality of carbon nanostructures. Each carbon nanostructure can include a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another.

Abstract: A composite for use in electromagnetic interference (EMI) shielding applications includes a carbon nanotube (CNT)-infused fiber material disposed in at least a portion of a matrix material. The composite is capable of absorbing or reflecting EM radiation, or combinations thereof in a frequency range from between about 0.01 MHz to about 18 GHz. The electromagnetic interference (EMI) shielding effectiveness (SE), is in a range from between about 40 decibels (dB) to about 130 dB. A method of manufacturing the composite includes disposing a CNT-infused fiber material in a portion of a matrix material with a controlled orientation of the CNT-infused fiber material within the matrix material, and curing the matrix material. A panel includes the composite and is adaptable to interface with a device for use in EMI shielding applications. The panel is further equipped with an electrical ground.

Abstract: A wire includes a plurality of carbon nanotube infused fibers in which the infused carbon nanotubes are aligned parallel to the fiber axes. An electromagnetic shield for a wire includes a plurality of carbon nanotube infused fibers, in which the infused carbon nanotubes are aligned radially about the fiber axes. The plurality of carbon nanotube infused fibers are arranged circumferentially about the wire with the fiber axes parallel to the wire. A self-shielded wire includes 1) a wire that includes a plurality of carbon nanotube infused fibers in which the infused carbon nanotubes are aligned parallel to the fiber axes; and 2) an electromagnetic shield that includes a plurality of carbon nanotube infused fibers in which the carbon nanotubes are aligned radially about the fiber axes. The axes of the carbon nanotube infused fibers of the wire and the carbon nanotube infused fibers of the electromagnetic shield share are parallel.

Abstract: A wire includes a plurality of carbon nanotube infused fibers in which the infused carbon nanotubes are aligned parallel to the fiber axes. An electromagnetic shield for a wire includes a plurality of carbon nanotube infused fibers, in which the infused carbon nanotubes are aligned radially about the fiber axes. The plurality of carbon nanotube infused fibers are arranged circumferentially about the wire with the fiber axes parallel to the wire. A self-shielded wire includes 1) a wire that includes a plurality of carbon nanotube infused fibers in which the infused carbon nanotubes are aligned parallel to the fiber axes; and 2) an electromagnetic shield that includes a plurality of carbon nanotube infused fibers in which the carbon nanotubes are aligned radially about the fiber axes. The axes of the carbon nanotube infused fibers of the wire and the carbon nanotube infused fibers of the electromagnetic shield share are parallel.

Abstract: A carbon nanostructure that is free of a growth substrate adhered to the carbon nanostructure can include a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another. Carbon nanostructures can be agglomerated with one another and densified to form a carbon nanostructure layer in which at least a portion of the carbon nanotubes in each carbon nanostructure are aligned substantially parallel to one another. Methods for forming a carbon nanostructure layer can include providing a plurality of carbon nanostructures that are free of a growth substrate adhered to each carbon nanostructure, and forming a carbon nanostructure layer by depositing the carbon nanostructures on a surface.

Abstract: A shielded wire includes a carbon nanostructure (CNS)-shielding layer including a CNS material in a matrix material, the CNS-shielding layer being monolithic and disposed about a dielectric layer and a conducting wire, wherein the dielectric layer is disposed between the CNS-shielding layer and the conducting wire. An extruded thermoplastic jacket includes a CNS material, the extruded thermoplastic jacket being configured to protect at least one wire. A thermoplastic article includes a CNS-infused fiber material and a flexible thermoplastic.

Abstract: Carbon nanostructures can convey enhanced electrical conductivity to various substrates, while maintaining a high surface area and low density per unit area. Such substrates can provide good shielding against electromagnetic radiation over a wide range of frequencies. Electrically conductive structures can include a support layer containing a plurality of fibers having apertures defined between the fibers, and a plurality of carbon nanostructures at least partially conformally coating the fibers and bridging across the apertures defined between adjacent fibers to form a continuous carbon nanostructure layer. Each carbon nanostructure can include a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another.

Abstract: A quality control system for the manufacture of carbon nanostructure-laden substrates includes a resistance measurement module for continuously measuring resistance of the carbon nanostructure (CNS)-laden substrate.

Abstract: Described herein are multi-functional composite materials containing energy storage assemblies that can be significantly resistant to tension/compression stress. The energy storage assemblies can contain at least one energy storage layer that contains an insulating layer having a plurality of openings arranged in a spaced apart manner, and a plurality of energy storage devices, each energy storage device being contained within one of the openings. The energy storage devices can be electrically connected to one another. The energy storage layer can contain a support material upon which electrical connections are formed. One or more energy storage layers can be disposed between two or more stress carrying layers to form an energy storage assembly that can have significant resistance to tension/compression stress. Energy storage devices suitable for use in the energy storage assemblies can include, for example, batteries, capacitors and/or supercapacitors.

Abstract: A composition includes a carbon nanotube (CNT) yarn or sheet and a plurality of carbon nanostructures (CNSs) infused to a surface of the CNT yarn or sheet, wherein the CNSs are disposed substantially radially from the surface of the CNT yarn or outwardly from the sheet. Such compositions can be used in various combinations in composite articles.

Abstract: Carbon nanotube-infused fiber materials containing substantially parallel-aligned, infused carbon nanotubes are described herein. The carbon nanotube-infused fiber materials contain a fiber material and a layer of carbon nanotubes infused to the fiber material, where the infused carbon nanotubes are aligned substantially parallel to the longitudinal axis of the fiber material and at least a portion of the substantially parallel-aligned, infused carbon nanotubes are crosslinked to each other, to the fiber material, or both. Crosslinking can occur through covalent bonding or pi-stacking interactions, for example. The carbon nanotube-infused fiber materials can further contain additional carbon nanotubes that are grown on the layer of substantially parallel-aligned, infused carbon nanotubes. Composite materials containing the carbon nanotube-infused fiber materials and methods for production of the carbon nanotube-infused fiber materials are also described herein.