A comprehensive analysis on feasibility and economic viability of commercial-scale MXene synthesis

• Analysised the probable potential of MXenes is distinct areas. • Summarized the current MXene synthesis methods. • Covered the challenges in commercial scale MXene production. • A comprehensive feasibility analysis was performed on MXene synthesis. MXenes, a class of two-dimensional materials, exhibit exceptional electrical conductivity, catalytic activity, and rapid charge-discharge characteristics, making them highly promising for energy-related applications, such as supercapacitors, batteries, water splitting, and fuel cell catalysis. Despite extensive research on the physicochemical properties and laboratory-scale synthesis of MXenes, a critical gap remains in understanding the feasibility and economic viability of commercial-scale MXene production. This study addresses this gap by systematically evaluating precursor materials, synthesis routes, scalability constraints, and environmental impacts associated with the manufacturing of MXenes. Through a comparative analysis of synthesis parameters and process economics, critical factors influencing consistent large-scale production were identified. The results demonstrate that optimized acid etching and post-processing methods can achieve high yield and reproducible MXene synthesis, effectively addressing significant scalability challenges. Compared with previous laboratory-focused studies, these findings provide more substantial evidence that industrial-scale MXene production can be both technically feasible and economically viable. The accompanying economic assessment further indicates cost-effectiveness, while market analysis reveals increasing demand across the energy, environmental, and electronic sectors. By integrating insights from technical optimization, cost modeling, and market trends, this work establishes a practical framework for advancing the industrialization of MXene. Overall, the study bridges the gap between laboratory research and real-world application, offering actionable guidance for achieving scalable, sustainable, and commercially competitive MXene manufacturing.