There are challenges of how to realize large-scale fabrication of high-quality graphene macrostructures and large-size single crystal graphene domains, which are essential for mass and device applications. In order to commercialize graphene materials, we developed a solid state intercalation-high temperature expansion-liquid phase exfoliation process. With a proto-type production line, 5 kg/day graphene material with high electrical conductivity can be produced, which will have wide applications in composites, energy storage, conductive inks, etc. Second, we developed an ambient pressure CVD to synthesize millimeter-size single crystal graphene grains and films on Pt substrates, and an electrochemical bubbling method to transfer these grains and films, which is also nondestructive to the Pt substrates that can be repeatedly used for graphene growth with no limit. The single crystal graphene grains has high crystallinity and high electrical mobility. The kinetics and edge control of the graphene grains were elucidated. Finally, in order to obtain graphene by CVD in a relatively large quantity, we tried to use Ni particles and Ni foams as substrates. Interestingly, with a Ni foam as template, a 3D graphene macrostructure, which is called graphene foam (GF), can be synthesized. This porous graphene bulk material consists of an interconnected network of graphene, is flexible, and has outstanding electrical and mechanical properties. And it can be used in elastic conductors, sensors, flexible lithium ion batteries, Li-S batteries, electromagnetic interference fielding materials, etc. 

There are challenges of how to realize large-scale fabrication of high-quality graphene macrostructures and large-size single crystal graphene domains, which are essential for mass and device applications. In order to commercialize graphene materials, we developed a solid state intercalation-high temperature expansion-liquid phase exfoliation process. With a proto-type production line, 5 kg/day graphene material with high electrical conductivity can be produced, which will have wide applications in composites, energy storage, conductive inks, etc. Second, we developed an ambient pressure CVD to synthesize millimeter-size single crystal graphene grains and films on Pt substrates, and an electrochemical bubbling method to transfer these grains and films, which is also nondestructive to the Pt substrates that can be repeatedly used for graphene growth with no limit. The single crystal graphene grains has high crystallinity and high electrical mobility. The kinetics and edge control of the graphene grains were elucidated. Finally, in order to obtain graphene by CVD in a relatively large quantity, we tried to use Ni particles and Ni foams as substrates. Interestingly, with a Ni foam as template, a 3D graphene macrostructure, which is called graphene foam (GF), can be synthesized. This porous graphene bulk material consists of an interconnected network of graphene, is flexible, and has outstanding electrical and mechanical properties. And it can be used in elastic conductors, sensors, flexible lithium ion batteries, Li-S batteries, electromagnetic interference fielding materials, etc.