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<p>Roll-to-roll (R2R) continuous fabrication is a highly promising method for industrial-scale graphene production due to its potential for uninterrupted throughput. However, synthesizing high-quality graphene at a high production rate under atmospheric pressure remains a major challenge. In this work, we identified low-temperature nucleation as a critical factor impairing graphene quality under industrial reactor conditions and addressed this by engineering a dual-suppression strategy: increasing graphene nucleation barrier via pre-annealing Cu in an oxidizing atmosphere and deploying a localized nozzle design to confine CH<sub>4</sub> supply directly to the high-temperature reaction zone. This synergistic approach enabled the continuous synthesis of monolayer graphene on a 26-cm-wide commercial Cu foil at a winding speed of 30 mm min<sup>−1</sup> under atmospheric pressure. The resulting graphene exhibited &gt; 95% monolayer coverage and low defect density, which showed a D/G intensity ratio &lt; 3%, as confirmed by Raman spectroscopy. Our work provides a feasible strategy for high-throughput and high-quality graphene manufacturing, representing a significant step toward bridging the gap between laboratory-scale synthesis and industrial mass production.</p>

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Industrial-scale roll-to-roll graphene fabrication: Nucleation control for high-speed, low-defect growth at atmospheric pressure

  • 期刊论文

  • 发表日期：

    2026年4月23日

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  • Qing He,
  • Lina Chen,
  • Lihong Ao,
  • Fangzhu Qing,
  • Fengning Liu,
  • Xuesong Li

摘要

Roll-to-roll (R2R) continuous fabrication is a highly promising method for industrial-scale graphene production due to its potential for uninterrupted throughput. However, synthesizing high-quality graphene at a high production rate under atmospheric pressure remains a major challenge. In this work, we identified low-temperature nucleation as a critical factor impairing graphene quality under industrial reactor conditions and addressed this by engineering a dual-suppression strategy: increasing graphene nucleation barrier via pre-annealing Cu in an oxidizing atmosphere and deploying a localized nozzle design to confine CH4 supply directly to the high-temperature reaction zone. This synergistic approach enabled the continuous synthesis of monolayer graphene on a 26-cm-wide commercial Cu foil at a winding speed of 30 mm min−1 under atmospheric pressure. The resulting graphene exhibited > 95% monolayer coverage and low defect density, which showed a D/G intensity ratio < 3%, as confirmed by Raman spectroscopy. Our work provides a feasible strategy for high-throughput and high-quality graphene manufacturing, representing a significant step toward bridging the gap between laboratory-scale synthesis and industrial mass production.