Long considered among the promising materials of the modern technological era, new research on carbon nanotubes (CNTs) has demonstrated a scalable manufacturing process. The Spanish study on CNT fibers has shown that these have electrical conductivity which is comparable to that of copper and aluminium, propelling this electrification technology in aerospace, EVs and drones.
Borys Stulii
20 July 2026
Their unique combination of low density and electrical, thermal and mechanical properties make carbon nanotubes (CNTs) an ideal building block for electrical conductors. Despite their small size, they are already influencing industries ranging from electronics to aerospace. Yet so far, CNTs have not been considered a realistic alternative to copper at an industrial scale. A new study could change this.
New research by IMDEA Materials Institute in collaboration with the Technical University of Madrid (UPM) and the University of Zaragoza at the INMA (CSIC-Unizar) have shown that CNTs have a significantly improved weight-to-performance ratio and that their absolute conductivity levels meet industrial requirements. The study which was published in Science (https://www.science.org/doi/10.1126/science.aeb0673) could be the key to transforming industries like aerospace, electronics and battery technology, which require lightweight and high-strength electrical wiring.
“This is the first time that researchers have produced results with CNT fibers demonstrating sufficient performance in this regard to offer a realistic industrial alternative to traditional conductive materials,” according to IMDEA Materials Principal Investigator, Dr. Juan José Vilatela, one of the authors behind the recent Science publication.
Global carbon nanotubes manufacturing has increased rapidly over the past few years, with LG Chem among the leading producers. While production capacity is rapidly scaling, widespread adoption faces hurdles from high manufacturing costs, processing challenges, and environmental health risks. As research progresses to overcome these limitations, CNTs are poised to be a critical component in future high-performance applications.
Carbon nanotubes are extremely small cylindrical structures made entirely of carbon atoms. They can be imagined as sheets of graphene — a single layer of carbon atoms arranged in a hexagonal pattern — rolled into tubes. Their diameter is measured in nanometres, while their length can reach several micrometres. This gives them an unusual “long and thin” structure.
CNTs were first discovered by Japanese physicist Sumio Iijima in 1991. Soon after, there was a flurry of excitement surrounding them. The scientific community put forward various theories about their applications. But it wasn’t until 2012 that manufacturers developed more practical methods for combining carbon nanotubes. Following further research, they proved to be particularly useful in the aerospace industry.
CNTs are much lighter than traditional materials such as copper, yet they offer high strength and conductivity. They are about 10% the weight of copper, which makes them ideal for reducing the weight of aircraft and spacecraft. It significantly lowers fuel consumption and costs. CNTs are also used in thermal management systems, radiation shielding, and advanced coatings that absorb light. They are easy to remove and only 2% of CNTs in a composite material can make it conductive enough to be used in space.
CNTs can save energy at temperatures from -60 to +100 °C. Furthermore, they are 50 times stronger than steel, which makes scientists research their future potential in futuristic technologies, such as space elevators.
Carbon nanotubes have been used in producing lithium-ion batteries. CNTs can improve electrical conductivity and help maintain the structure of the electrodes, thereby increasing the charging rate of batteries for EVs. Furthermore, CNTs bring a longer lifespan to batteries and enhance composite electrode safety, preventing thermal runaways. Finally, lightweight and larger surface area make them beneficial compared to other conductive materials. For example, 3-4kg of carbon black electrodes used in batteries for EVs can be replaced with 1kg of CNTs. This in turn will reduce the price for manufacturing.
Beyond batteries, carbon nanotubes are used in electronics. They can function as tiny wires, transistors, or sensors. Their sensitivity allows them to detect molecules in gases or liquids, making them useful for environmental monitoring, medical diagnostics, and security applications. In optics, they are applied in displays and light-emitting devices, while in mechanics, they are used to create ultra-strong fibers and composite materials.
Despite these advantages, carbon nanotubes also present several challenges. One of the main drawbacks is cost. Producing high-quality nanotubes requires complex and energy-intensive processes. This limits their widespread adoption, making them cost more than lithium-ion technology.
Another issue is processing. Carbon nanotubes tend to stick together, forming clusters that are difficult to disperse evenly. Achieving a uniform distribution is essential for consistent performance, particularly in composite materials and batteries. In addition, impurities from the manufacturing process can reduce their effectiveness and require further purification steps.
Health and environmental concerns also need to be considered. Some studies suggest that certain types of carbon nanotubes, particularly long multi-walled varieties, may behave similarly to asbestos fibers when inhaled. Due to their small size, they can enter the respiratory system and accumulate in the lungs, potentially causing harmful effects over time.
Despite these challenges, the future of carbon nanotubes appears bright. Production capacity has increased significantly over the past two decades, with global output expanding as demand grows. This trend is expected to continue, leading to lower costs and broader adoption.
The recent Spanish study is a new promising development for CNT fiber technology. It showed that gas-phase intercalation can increase the conductivity of commercial CNT fibers substantially above their previous ceiling, offering both record-high electrical conductivity, and the prospect of further increases. This is particularly significant for new transportation technology, be it EVs, drones or aircraft, which require a large number of conductors at the lowest possible weight.
