What are the most common challenges of leveraging carbon nanomaterials at scale?

The use of carbon nanomaterials, particularly graphene-based structures, has unlocked new possibilities in biosensor technology, energy storage and various industrial applications. Their electrical conductivity, high surface area and chemical stability make them uniquely suited for applications requiring high levels of sensitivity. However, scaling up their production for widespread use whilst maintaining quality and cost-effectiveness presents significant challenges. 

Engineers need a clear understanding of the key hurdles in commercialising carbon nanomaterials for biosensor manufacturing, with a focus on cost constraints, reproducibility, environmental impact and technical challenges. 

Cost constraints

The production of high-quality carbon nanomaterials is expensive as a result of the complexity of synthesis techniques. Traditional methods such as chemical vapor deposition (CVD) and liquid-phase exfoliation require significant energy input and expensive raw materials, making large-scale adoption cost-prohibitive. In biosensor manufacturing, the high cost of carbon nanomaterials can be a major deterrent for widespread implementation. 

• Graphene: CVD-grown graphene, often considered the highest quality form, is particularly expensive due to the need for advanced equipment, high-temperatures (~1000 °C) and energy hungry processes.
• Carbon Nanotubes (CNTs): Single-walled CNTs are highly desirable for biosensors due to their superior conductivity, but their production involves intricate synthesis methods such as arc discharge or laser ablation, further escalating costs.

Batch to batch reproducibility

Maintaining consistency in material properties across different production batches is a persistent challenge. Minor variations in synthesis conditions can lead to significant deviations in electronic, chemical and structural properties, which in turn impact biosensor performance. This makes reproducibility a critical factor in applications where sensors must reliably detect biomarkers at extremely low concentrations. Unfortunately, traditional carbon nanomaterials face significant challenges in this area. 

• Graphite-derived materials: The variability in graphite feedstocks can introduce inconsistencies in exfoliated graphene or graphene oxide production.
• Graphene: Variations in CVD growth conditions (e.g., temperature, pressure, gas flow rates) lead to discrepancies in layer number, defect density and electrical properties. Transferring the CVD graphene to final integration is also challenging and can result in variability.
• Carbon Nanotubes: CNT synthesis often results in a mixture of metallic and semiconducting tubes, requiring additional sorting steps to ensure uniformity, which is difficult to scale reliably. Additionally, CNTs suffer from the same inconsistencies that graphite-derived materials face, and also require binders that increases the complexity of production and hinders reproducibility. 

Environmental and sustainability concerns 

The environmental impact of large-scale carbon nanomaterial production is another concern. Many synthesis processes involve hazardous chemicals, generate toxic byproducts and require high energy consumption. Sustainable alternatives, such as green synthesis methods and recyclable nanomaterials, are gaining traction but require further research and industrial validation. 

• Graphite mining: A major source of raw materials, graphite mining can lead to significant environmental damage, including habitat destruction and groundwater contamination.
• Graphene production: Methods such as oxidation-reduction (used in graphene oxide synthesis) generate hazardous waste, including strong acids and organic solvents.
• Carbon nanotubes: Large-scale production via chemical vapor deposition has significant power requirements, and the disposal of CNTs remains a concern due to potential toxicity.

Biofouling and long-term stability

One of the significant challenges in leveraging carbon nanomaterials for biosensor applications is biofouling. Biofouling occurs when biological molecules, such as proteins, lipids and microorganisms, accumulate on the sensor surface, affecting its sensitivity and accuracy over time. This is particularly problematic for medical diagnostics, where biosensors must maintain precision over extended periods.

• Carbon nanotubes: CNTs are prone to biofouling due to their strong interactions with biomolecules.
• Graphite-based electrodes: These materials tend to accumulate biofilm layers over time, which can interfere with electrochemical measurements and necessitate frequent sensor recalibration.

How new carbon nanomaterials are overcoming these challenges

Innovations in carbon nanomaterials present a breakthrough in scalable production by addressing these challenges effectively. As industries struggle with the high costs, inconsistencies and environmental impact of existing methods, materials like Gii offer a solution that optimises (and balances) both performance and manufacturability. Unlike traditional methods, which often lead to significant material wastage and require energy-intensive processes, Gii’s technology streamlines production whilst ensuring high reproducibility with minimal batch-to-batch variation. 

• Cost-effective manufacturing: The production process is designed to be energy-efficient and does not require rare or expensive precursors.
• Consistent performance: Gii's approach ensures high batch consistency, making it ideal for biosensor applications where reliability is paramount.
• Sustainable production: With a low carbon footprint and reduced reliance on hazardous chemicals, Gii aligns with global sustainability goals.
• Antifouling properties: The material is designed to resist biofouling, reducing the accumulation of proteins and other biological materials that can degrade sensor performance.

Integrate a carbon nanomaterial that is free of the traditional challenges

Scaling carbon nanomaterials for biosensor manufacturing presents a range of challenges, from high costs and reproducibility issues to environmental concerns. However, with continuous advancements in production methods and materials engineering, solutions such as Gii are paving the way for a more scalable and commercially viable approach. 

As the industry moves toward broader adoption, balancing performance, affordability and sustainability will be key to unlocking the full potential of carbon nanomaterials in biosensor technology and beyond. To learn more about Gii and its innovative capabilities, download our guide below.