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Polymer nanocomposites based on 2D materials as fillers are the target in theindustrial sector, but the ability to manufacture them on a large scale is verylimited, and there is a lack of tools to scale up the manufacturing process ofthese nanocomposites. Here, for the first time, a systematic and fundamentalstudy showing how 2D materials are inserted into the polymeric matrix in orderto obtain nanocomposites using conventional and industrially scalable polymerprocessing machines leading to large-scale manufacturing are described. Two newstrategies were used to insert pre-exfoliated 2D material into the polymermatrix, liquid-phase feeder, and solid-solid deposition. Characterizations werebeyond micro and nanoscale, allowing the evaluation of the morphology formillimeter samples size. The methodologies described here are extendable to allthermoplastic polymers and 2D materials providing nanocomposites with suitablemorphology to obtain singular properties and also triggering the start of themanufacturing process on a large scale.

Polymer/2D material nanocomposite manufacturing beyond laboratory frontiers