Paving continuous thermal conduction pathway for flexible composite materials

Flexible thermally conductive composites (FTCs), as a new generation of thermal management materials, have shown tremendous potential for applications in flexible electronics, wearable devices, and biomedical engineering. This paper systematically reviews the design strategies, manufacturing techniques, and application progress of FTCs. Starting from the mechanisms of heat conduction, the paper provides a detailed analysis of the effects of polymer matrices and various fillers on the thermal and mechanical properties of the materials. The review focuses on the latest research achievements in synergistically optimizing high thermal conductivity and excellent flexibility through strategies such as filler alignment engineering, three-dimensional network construction, and biomimetic structural design. Additionally, this paper comprehensively evaluates the advantages and disadvantages of traditional processing methods and advanced manufacturing technologies, along with their impact on material performance. Furthermore, an in-depth analysis is conducted on the applications of FTCs in flexible electronic heat dissipation, wearable device thermal management, energy systems, and biomedical engineering, with an emphasis on their performance in practical application scenarios. Despite significant progress in FTCs research, this paper also identifies key challenges currently faced, including the balance of thermal conductivity and flexibility, scalability of manufacturing processes, and long-term stability. Finally, future development directions, such as machine learning-assisted design, multifunctional integration, and sustainable materials, are discussed. This review not only provides a systematic theoretical framework for the fundamental research of FTCs, but also offers valuable insights for the engineering applications of related materials.