The novel properties of carbon nanotubes have generated scientific and technical interest in the development of nanotube-reinforced polymer composites. In order to utilize nanotubes in multi-functional material systems it is crucial to develop processing techniques that are amenable to scale-up for high volume, high rate production. In this research we investigate a scalable calendering approach for achieving dispersion of CVD-grown multi-walled carbon nanotubes through intense shear mixing. Electron microscopy was utilized to study the micro and nanoscale structure evolution during the manufacturing process and optimize the processing conditions for producing highly-dispersed nanocomposites. After processing protocols were established, nanotube/epoxy composites were processed with varying reinforcement fractions and the fracture toughness and electrical/thermal transport properties were evaluated. The as-processed nanocomposites exhibited significantly enhanced fracture toughness at low nanotube concentrations. The high aspect ratios of the carbon nanotubes in the as-processed composites enabled the formation of a conductive percolating network at concentrations below 0.1 percent by weight. The thermal conductivity increased linearly with nanotube concentration to a maximum increase of 60 percent at 5 wt. percent carbon nanotubes.
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