Multi-walled carbon nanotubes (CNTs) were synthesized on Fe-Ni-Co alloy-coated glass substrates by thermal chemical vapor deposition at 550 degreesC. Thickness of the Al and catalyst markedly affected the growth rates, diameters, and population density of CNTs. The catalyst thickness had a greater effect on diameter and growth rate than that of Al. The population density of CNTs was governed mainly by the Al thickness. The Al and catalyst thickness were optimized in terms of field emission characteristics to grow the CNTs in the gated field emitter arrays. The smaller diameters and lower density of CNTs resulted in the best emission characteristics. (C) 2004 Elsevier B.V. All rights reserved.