Advanced Flame Spray Pyrolysis (FSP) Technologies for Engineering Multifunctional Nanostructures and Nanodevices

Abstract

Flame spray pyrolysis (FSP) is an industrially scalable technology that enables the engineering of a wide range of metal-based nanomaterials with tailored properties nanoparticles. In the present review, we discuss the recent state-of-the-art advances in FSP technology with regard to nanostructure engineering as well as the FSP reactor setup designs. The challenges of in situ incorporation of nanoparticles into complex functional arrays are reviewed, underscoring FSP’s transformative potential in next-generation nanodevice fabrication. Key areas of focus include the integration of FSP into the technology readiness level (TRL) for nanomaterials production, the FSP process design, and recent advancements in nanodevice development. With a comprehensive overview of engineering methodologies such as the oxygen-deficient process, double-nozzle configuration, and in situ coatings deposition, this review charts the trajectory of FSP from its foundational roots to its contemporary applications in intricate nanostructure and nanodevice synthesis.

Advances in flame synthesis of nano-scale architectures for chemical, biomolecular, plasmonic, and light sensing

“…, CO, NO x , NH 3 , acetone, ethanol) with enhanced selectivity and sensitivity, 68,157 and biosensing, where the high surface-to-volume ratio of the nanoparticles enables the effective capturing and signaling of biomolecules. 158 Compared to other methods, FSP is less time-consuming, rapid one-step fabrication, and can be utilized to produce nanoparticles with limited aggregation and a narrow size distribution, which in turn, ensures consistent and reliable sensing performance across various applications. The potent combination of adaptability, efficient synthesis, high purity of nanomaterials, cost effectiveness, and improved sensing capabilities solidifies FSP as a preferred choice in nanoparticle fabrication for chemical sensing technologies.…”

Industrial-Scale Engineering of Nano {RuO2/TiO2} for Photocatalytic Water Splitting: The Distinct Role of {(Rutile)TiO2–(Rutile)RuO2} Interfacing

“…To date, FSP has been extensively utilized in the production of most known metal oxides. 36,37 42,43 NaTaO 3 /NiO, 44 and PdO/Pd 0 /TiO 2 45 have been produced in one step. In the case of RuO 2 , due to the high volatility of Ru-atoms at elevated temperatures (T > 800 °C), such as those occurring in a typical FSP flame, 35 the formation of highly volatile oxides RuO 3 and RuO 4 rather than RuO 2 could be favored.…”

Flame Spray Pyrolysis Synthesis of Vo-Rich Nano-SrTiO3-x

“…In this context, flame spray pyrolysis (FSP) is a versatile technology for the engineering of multifunctional nanostructures and nanodevices [ 20 ] with controllable characteristics (size, phase, crystallinity), and can provide nanoparticles at large quantities. Recently, we have demonstrated that FSP can be successfully employed to synthesize highly-photoactive perovskite materials, e.g., BiFeO 3 [ 21 ], NaTaO 3 [ 22 ].…”

“…Herein, the specific aims of the present works were: (i) to develop FSP protocols for controlled Vo-engineering in nanosized SrTiO 3-x , employing an advanced FSP approach in which the combustion stoichiometry was controlled by the FSP-design and operating conditions [ 16 , 20 , 26 , 27 ]; (ii) to study the structural and spectroscopic properties of the so-produced SrTiO 3-x ; (iii) to extend and highlight the versatility of A-FSP as a technique capable of producing large quantities of elaborated nanostructures.…”