A major distinction between liquid-fed flame synthesis reactors can be made as a function of whether the reaction enthalpy is mainly provided via the precursor solution, often referred to as flame spray pyrolysis (FSP), or by a supporting flame, often cited as liquid-fed spray flame synthesis. Latter progress in flame synthesis reactor design partially converged to a majority of systems using liquid precursors as a convenient and flexible feedstock for the desired nanomaterials. įirst attempts to use flames for the fabrication of nanotextured layers have been largely related to the evolution of thermal spray reactors, with application mostly in the deposition of biocompatible and decorative coatings. ![]() While original application of flame synthesis has been almost entirely dedicated to the production of nanoparticle powders, the direct integration of flame-made materials in devices has rapidly advanced in the last decades, demonstrating potential for numerous applications, including fuel cells, chemical and light-sensing, (photo)electrocatalysis, biomedical and super-hydrophilic/hydrophobic coatings. Flame synthesis has a long implementation history accounting for both the first man-made nanomaterials with the reported production of nanopigments in sooting flames already in 3 rd century BC and the first large-scale production of nanoparticle commodities, including carbon black, fumed silica, pigmentary titania, and P25 catalysts. The three-dimensional self-assembly of porous textures of nanomaterials by the deposition of nanoparticle-loaded aerosols is increasingly considered a powerful approach for the fabrication and integration of non-silicon-based nanomaterials in devices.Īmongst emerging fabrication technologies for the generation of nanoparticle aerosols, the flame synthesis route provides some distinct features including a large range of feasible material compositions, one-step synthesis process, high scalability, and production rate. This is particularly challenging as, in addition to the vast range of potentially useful material compositions, it is often necessary to reproducibly fabricate non-planar mesoporous architectures with a hierarchy of functionality across multiple length scales. However, the feasibility of integrating various types of nanomaterials, and in particular catalysts, in devices is significantly less advanced, resulting in slow progress of critically needed technologies such as electrolysers for hydrogen production, point-of-care, and portable biomedical sensors, and high energy density storage batteries. In the past decades, silicon-based manufacturing has been dominant, ranging from the intricate design of CPUs with a size of a few cm 2 to the scale of km-wide photovoltaic solar farms. Recent progress in nanomanufacturing is leading the transformation of our information, defence, energy, and healthcare technologies, with nanomaterials having become critical building blocks for the next generation of microprocessors, optoelectronic devices, solar cells, high-capacity batteries, and biomedical sensors. ![]() We will conclude with an outlook towards possible implementation of flame-assisted self-assembly as a scalable tool for nanofabrication in emerging devices and a critical assessment of the persisting challenges for its broader industrial uptake. A selection of exemplary flame-made nanostructures will be presented across the major categories of catalysis, energy conversion devices, membranes and sensors, highlighting weakness and strengths of this synthesis route. The fundamentals of flame synthesis will be briefly reviewed to evaluate trends in flame reactor designs and directions for improvements. In this review, we present a perspective of recent progress in flame-assisted nanofabrication and its application to emerging technologies. ![]() In the past two decades, flexibility in nanomaterials and facile fabrication of nanostructured films by aerosol self-assembly has motivated the exploration of this technology for device applications. Amongst various nanofabrication approaches, the flame synthesis route accounts for some of the first man-made nanomaterials and industrial production of various nanoparticle commodities such as carbon black, fumed silica, and pigmentary titania. Development of fabrication technologies for three-dimensional structuring and integration of nanomaterials in devices is important for a broad range of applications, including next-generation high energy density batteries, super(de)wetting and biomedical coatings, and miniaturized biomedical diagnostics.
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