Cooperative and Ordered Cross-Scale Assembly of Carbon Nanotube Fibers

Carbon nanotube fibers (CNTFs) exhibit exceptional mechanical, electrical, and thermal properties, granting them broad application potential in aerospace, flexible electronics, and advanced composites. However, the performance of CNTFs produced by the FCCVD dry spinning method is far below the theoretical limit of a single carbon nanotube (CNTs). This gap is largely attributed to weak interfacial interactions between CNTs, catalyst residues, and multiscale structural defects. Conventional research has often focused on adjusting isolated process parameters and preparation strategies based on equilibrium-state assumptions, lacking a systematic grasp of non-equilibrium growth kinetics and the synergistic regulation of multi-physical fields. Therefore, this study explores the cooperative assembly of CNTFs through the lens of non-equilibrium states and multi-field synergy. It systematically reviews recent advances in CNTs synthesis and fiber optimization across three scales: the microscale (atomic-level growth mechanisms and interface modulation), the mesoscale (structural evolution and multi-physical field coupling during CNTs assembly), and the macroscale (bulk fiber properties). With a focus on enhancing CNTFs performance, the work outlines cross-scale structural regulation strategies. The aim is to provide theoretical support for future cross-scale modeling, reactor design optimization, and defect engineering, while offering a systematic reference and technical roadmap toward high-performance CNTFs and breakthrough property advancements.