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Nanoparticles are used in industrial and domestic applications to control customized product properties. But there are several uncertainties concerning possible hazard to health safety and environment. Hence, it is necessary to search for methods to analyze the particle release from typical application processes. Based on a survey of commercial sanding machines, the relevant sanding process parameters were employed for the design of a miniature sanding test setup in a particle-free environment for the quantification of the nanoparticle release into air from surface coatings. The released particles were moved by a defined airflow to a fast mobility particle sizer and other aerosol measurement equipment to enable the determination of released particle numbers additionally to the particle size distribution. First, results revealed a strong impact of the coating material on the swarf mass and the number of released particles.

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The performance of particle‐based products depends on a multiple set of particle properties. To monitor them during particle manufacturing, three novel aerosol measurement techniques were developed: wide‐angle light scattering (WALS), three‐dimensional laser scattering (3D‐LSS), and differential aerodynamic particle sizing (DAPS). They measure particle shape, aggregate structure, and particle size, i.e., radius of gyration and aerodynamic diameter. The techniques were tested for rod‐like organic pigments and partially sintered SiO2 aggregates, which were produced by two new aerosol generators.

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