Rapid and sustained growth of carbon nanotube forests through coupled support design and catalyst particle formation dynamics

Abstract

Achieving both fast and sustained growth of vertically aligned carbon nanotubes (CNTs) is crucial for their future applications, yet remains a formidable challenge due to the long-standing trade-off between growth rate and catalyst lifetime. Here, we overcome this limitation by precisely engineering the surface layer that contributes to catalyst stability (the “anchor layer”) and catalyst nanoparticle formation process. This combined approach enables a favorable catalyst array structure (size and spacing) to afford a high average growth rate (167 μm min⁻¹) and stable catalyst activity for up to 60 min, surpassing previously reported limits of CNT growth performance.