Composites of polymers and organized carbon nanotube (CNT) networks have been proposed as next-generation lightweight structural materials, yet polymer infiltration of CNT networks often results in stress-concentrating heterogeneities, due to local CNT aggregation or incomplete infiltration. During my PhD, I developed a new technique based on interfacial polymerization (IP), performed in-situ within CNT networks, to produce dense CNT-polymer composites with tailored polymer distribution. With in-situ interfacial polymerization (ISIP), polymers which are usually not easily processable, such as aramids (Kevlar, Nomex, etc.), can be introduced into dense CNT mats. Additionally, uniform polyamide-CNT composite sheets obtained by this method show a two-fold increase in elastic modulus and tensile strength compared to pristine CNT sheets.

The rapid rate and overall controllability of ISIP suggest its viability for formation of polymers within CNT networks via roll-to-roll methods. Importantly, ISIP features shorter processing times than direct polymer infiltration and preserves the morphology of the CNT network. Finally, ISIP is not limited to CNT networks - it can be used to obtain composites with controlled morphology of polymers and other porous materials such as electrospun nanofiber mats or foams.