Carbon nanotube (CNT)-reinforced polymer composites exhibit exceptional mechanical, electrical, and thermal properties, making them ideal for high-performance applications. This review critically examines recent advances in CNT dispersion, functionalization, and interfacial load transfer strategies, emphasizing hybrid functionalization, supercritical fluid processing, and polymer wrapping. Advanced characterization tools, such as scanning electron microscopy (SEM), Transmission Electron Microscopy (TEM), and Raman spectroscopy, are highlighted. Optimized dispersion techniques achieve up to 40% improvements in tensile strength and 2–3 orders of magnitude enhancement in electrical conductivity. The review also addresses industrial challenges, including scalability, reproducibility, and environmental sustainability, and outlines key applications in aerospace, automotive, electronics, energy storage, and biomedical sectors. Future directions for scalable processing and multifunctional composite design are proposed, enabling widespread adoption of CNT-polymer composites.
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