Three-dimensional graphene foam (3D GrF) is an interconnected, porous structure of graphene sheets with excellent mechanical, electrical and thermal properties, making it a candidate reinforcement for polymer matrices. GrF’s 3D structure eliminates nanoparticle agglomeration and provides seamless pathways for electron travel. The objective of this work is to fabricate low density GrF reinforced epoxy composites with superior mechanical and electrical properties and study the underlying deformation mechanisms. Dip coating and mold casting fabrication methods are employed in order to tailor the microstructure and properties. The composite’s microstructure revealed good interfacial interaction. By adding mere 0.63 wt.% GrF, flexural strength was improved by 56%. The addition of 2 wt.% GrF showed a surge in glass transition temperature (56oC), improvement in damping behavior (150%), and electrical conductivity 11 orders of magnitude higher than pure epoxy. Dip coated and mold casted composites showed a gauge factor of ~2.4 indicating electromechanically robust composite materials.
