It depends both on your application as well as your design. For lab scale preparations, to study mechanical properties, I would recommend the introduction of your CNC in to a resin base matrix. During this method, the main concern for CNC film preparation, is on CNC dispersion method. Recently some researches have been able to overcome this challenge by applying ultrasonic waves during the film formation. Moreover, if you are planning to use CNC itself, then you can build your own molds with various dimensions and pour your dilution (CNC+water) into the mold and test your films performances based on your goals.
the film composed of cellulose nanocrystals can be prepared in water and DMF, but the film is fragile. However, The film of bacterial cellulose membrane has better ductility and strength.
When you have decided on an appropriate matrix within which to infuse or mix, the cast method in petri dishes and the like could be used. CNC could be aligned by electromagnetism before setting or curing of matrix.
You can make by using Polyvinyl Alcohol and mixing together at 80oC for 3 hours and put on petri dish or glass plate, control the thickness, degassing in vaccum desicator and dry in oven for 12 hours.
It depends on your applications and what you are looking for. You are considering of making pure CNC film or CNC based film?
For pure CNC film, you can use casting method. CNC suspensions after preparation were poured into molds and allowed to evaporate the water in dust control atmosphere. CNC solid films weights and thickness can be control by the amount of the suspension as well as its concentration. You can also generate CNC film with optical properties. The optical properties of the CNC solid films cannot be reproduced by printing or photocopying, therefore, these solid films will have numerous potential applications such as coating materials for decorative materials and security papers.
On the other hand, if you looking for CNC based films, several different methods can be utilized such as casting, molding, compression etc. In this case, you might need to disperse CNC in solvent, polymer, media etc.
The CNC films are quite stable, of course depending on type of film, which can be stable in different conditions.
I have tried to disperse the CNC in water and using the ultrasonicator, however I failed to get a suspension or a dense solution which could be casted. perhaps if you could provide references where CNC was suspended in water and casted, as I am trying make a green material.