CVD nanocrystalline multilayer graphene coated 3D-printed alumina lattices

3D printing technologies have expanded the possibilities of fabricating new composite materials with tailored properties, which depend on both the materials selected and the structural design at multiple length scales. Here, a catalyst-free CVD method has been used to produce hybrid materials based on 3D printed cellular α-Al₂O₃ substrates decorated by either nanocrystalline graphene or nanocrystalline graphitic films of tunable number of layers. Graphene-based coatings of variable thickness and crystallinity have been controlled by the alteration of the parameters of CVD processing, performed under CH₄/H₂ flux. Transmission electron microscopy has confirmed the effective growth of nanocrystalline graphene layers on the scaffolds due to the penetration of CVD gases into the open pores. The fully-connected and highly conductive 3D pathways have displayed a room temperature electrical conductivity in the range of 10¹–10³ S m⁻¹. Furthermore, the thermal conductivity has also increased by 50% for the specimen decorated with a 20 nm thick graphitic coating as compared to a bare 3D ceramic scaffold. The developed structures open up new possibilities for expanding the field of application of graphene/ceramic composites for conditions requiring dielectric substrates of various shapes coated with conductive films or graphene-based catalytic supports with good structural stability.