Aerosol CVD Carbon Nanotube Thin Films: From Synthesis to Advanced Applications: A Comprehensive Review

Carbon nanotubes (CNTs) produced by the floating-catalyst chemical vapor deposition (FCCVD) method are among the most promising nanomaterials of today, attracting interest from both academic and industrial sectors. These CNTs exhibit exceptional electrical conductivity, optical properties, and mechanical resilience due to their binder-free and low-defect structure, while the FCCVD method enables their continuous and scalable synthesis. Among the methodological FCCVD variations, aerosol CVD’ is distinguished by its production of freestanding thin films comprising macroscale CNT networks, which exhibit superior performance and practical applicability. This review elucidates the complex interrelations between aerosol CVD reactor synthesis conditions and the resulting properties of the CNTs. A unified approach connecting all stages of the synthesis process is proposed as a comprehensive guide. This review examines the correlations between CNT structural parameters (length and diameter) and resultant film properties (conductivity, optical, and mechanical characteristics) to establish a comprehensive framework for optimizing CNT thin film synthesis. The analysis encompasses characterization methodologies specific to aerosol CVD-synthesized CNTs and evaluates how their properties influence applications across diverse domains, from energy devices to optoelectronics. The review concludes by addressing current challenges and prospects in this field.