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The growth in activity surrounding nanomaterials The nanotechnology bandwagon continues to roll.
continues unabated as more R&D funds are poured The number of individuals and groups active in this
field continues to grow as funding, especially for
into nanotechnology and companies look to exploit
government-supported work, continues to rise. It has
the expanding range of novel properties that are
been estimated that $8.6 billion will be spent
being discovered. Advances in existing production worldwide on nanotechnology-related R&D in 2004,
techniques are improving the quality and yields, of which just over half ($4.6 billion) is from
providing a clear prospect of commercially viable governmental bodies1. A consequence of this is the
volume production. There is still a wide range of accelerating number of publications and patents2
processes being used, and it is clear those that will be coming out each year (Fig. 1).
commercially successful will be those for which the
An added incentive to researchers developing applications,
materials have been developed at the same time as especially budding entrepreneurs, is the talk of
the application. Recent reports from a number of nanotechnology companies going public and the high share
working groups have highlighted the need for values associated with them, although this has taken a
tumble in recent months. The drive behind nearly all this
increased examination of the health, environmental, activity is the continued development of nanomaterials and
and ethical aspects of nanotechnology, and this is an the constant stream of new properties and capabilities that
area that the industry will need to understand more are being discovered. These innovations appear to make
possible an ever-increasing number of applications for which
fully and take appropriate action on if the benefits of
nanomaterials can provide improved performance and the
nanomaterials are to be realized. promise of competitive advantage and value creation. In
many areas where the industries are mature, such as
automotives, commodity plastics, and power generation, the
slightest advantage over one’s competitors can mean the
difference between struggling to survive and a sustainable
existence. The use of nanomaterials in these industries and
others is increasingly being seen as one way of gaining this
QinetiQ Nanomaterials Ltd,
Y25 Bldg, Cody Technology Park, advantage in the marketplace.
Ively Road, Farnborough, Hants GU14 0LX, UK However, nanotechnology is not new and, although the
E-mail: mjpitkethly@QinetiQ.com
URL: www.nano.QinetiQ.com term was first coined in the 1960s, it can be argued that
December 2004 21
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(a) (b)
(c) (d)
Fig. 2 Micrographs of different example nanomaterials: nanopowders of (a) Co; (b) copper oxide; (c) ZnO; and (d) Ag.
applications where the physical size of the particle can Wet chemical processes
provide enhanced properties that are of benefit are extremely These include colloidal chemistry, hydrothermal methods,
wide. Some of the applications that utilize these sol-gels, and other precipitation processes. Essentially,
characteristics are discussed later in this article. solutions of different ions are mixed in well-defined
quantities and under controlled conditions of heat,
How are nanoparticles made? temperature, and pressure to promote the formation of
Manufacturing nanoparticles can be achieved through a wide insoluble compounds, which precipitate out of solution. These
variety of different routes: some have been around for many precipitates are then collected through filtering and/or spray
years; others are far more recent. In essence, there are four drying to produce a dry powder.
generic routes to make nanoparticles: wet chemical, The advantages of these wet chemical processes are that a
mechanical, form-in-place, and gas-phase synthesis. It is large variety of compounds can be fabricated, including
worth exploring each of these basic routes, as the resultant inorganics, organics, and also some metals, in essentially
materials can have significantly different properties, cheap equipment and significant quantities. Another
depending on the route chosen to fabricate them, and some important factor is the ability to control particle size closely
routes are more aligned with the fabrication of certain and to produce highly monodisperse materials. However,
classes of materials. there are limitations with the range of compounds possible,
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Fig. 3 Nanostructures of ZnO synthesized under controlled conditions by thermal evaporation of solid powders9.
bound water molecules can be a problem, and, especially for An adjunct to these processes are those involving
sol-gel processing, the yields can be quite low. biological materials that provide a template into which
New processes that might overcome some of these inorganic materials can be grown. Since biological materials,
problems are being developed, such as high-throughput such as porphyrin13 and ferritins14, are highly reproducible,
microreactors12. For bulk production, large quantities of the resulting nanomaterials can be made to an extremely
starting materials may be required, which can be expensive. specific size with a high degree of accuracy. However, the
Having the nanoparticles well dispersed in a suspension, range of sizes may be limited by the availability and structure
however, is an advantage if further surface treatment is of suitable template materials. These are being used to
required to encapsulate or functionalize their surface. manufacture materials such as magnetic materials for use in
high-density storage devices.
Table 1 Characteristic lengths in solid-state science model10. Mechanical processes
Field Property Scale length These include grinding, milling, and mechanical alloying
Electronics Electronic wavelength 10-100 nm techniques. Provided that one can produce a coarse powder
Inelastic mean free path 1-100 nm as a feedstock, these processes utilize the age-old technique
Tunneling 1-10 nm
of physically pounding coarse powders into finer and finer
Magnetics Domain wall 10-100 nm
Spin-flip scattering length 1-100 nm ones, similar to flour mills. Today, the most common
Optics Quantum well 1-100 nm processes are either planetary or rotating ball mills. The
Evanescent wave decay length 10-100 nm
advantages of these techniques are that they are simple,
Metallic skin depth 10-100 nm
Superconductivity Cooper pair coherence length 0.1-100 nm require low-cost equipment and, provided that a coarse
Meisner penetration depth 1-100 nm feedstock powder can be made, the powder can be processed.
Mechanics Dislocation interaction 1-1000 nm However, there can be difficulties such as agglomeration of
Grain boundaries 1-10 nm
Crack tip radii 1-100 nm the powders, broad particle size distributions, contamination
Nucleation/growth defect 0.1-10 nm from the process equipment itself, and often difficulty in
Surface corrugation 1-10 nm
getting to the very fine particle sizes with viable yields. It is
Catalysis Surface topology 1-10 nm
commonly used for inorganics and metals, but not organic
Supramolecules Kuhn length 1-100 nm
Secondary structure 1-10 nm materials.
Tertiary structure 10-1000 nm Form-in-place processes
Immunology Molecular recognition 1-10 nm
These include lithography, vacuum deposition processes
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such as physical vapor deposition (PVD) and chemical vapor nanotubes. All are being used, some commercially, and each
deposition (CVD), and spray coatings. These processes are has its merits and drawbacks. However, it is clear that most
more geared to the production of nanostructured layers and of the methods will be utilized in commercial production at
coatings, but can be used to fabricate nanoparticles by some stage since, although the materials are nominally the
scraping the deposits from the collector. However, they tend same, the characteristics of the materials produced by each
to be quite inefficient and are generally not used for the process are not always equivalent and can have different
fabrication of dry powders, although some companies are properties. The manufacturing routes that become
beginning to exploit these processes. A number of universities commercially successful, therefore, will predominantly be
and companies are developing variations on these processes, those for which the materials have been developed at the
such as the electrostatic spray assisted vapor deposition same time as the application.
process15.
Gas-phase synthesis Growth in commercial activity
These include flame pyrolysis, electro-explosion, laser Adding particulate materials to other matrix materials has
ablation, high-temperature evaporation, and plasma synthesis been a common technique for changing the properties of
techniques. materials since the human race first developed synthetic
Flame pyrolysis has been used for many years in the materials. However, the additives first used were usually
fabrication of simple materials such as carbon black and larger than the nanoscale.
fumed silica, and is being used in the fabrication of many The first industrial production of nanomaterials occurred
more compounds. Laser ablation is capable of making almost early in the 20th century with the production of carbon black
any nanomaterial, since it utilizes a mix of physical erosion and subsequently, in the 1940s, fumed silica. These materials
and evaporation. However, the production rates are are still produced and used in vast quantities, and some well-
extremely slow and most suited to research uses. Both RF known companies such as Degussa and Cabot owe their
and DC plasmas are being used successfully to make a wide origins to these materials. However, it was not until the
range of materials. The heat source is very clean and latter half of the 20th century that the scientific
controllable and the temperatures in the plasmas can reach understanding of materials incorporating ultrafine
in excess of 9000°C, which means that even highly refractory particulates really developed and it was realized that
materials can be processed. However, this also means that significant improvements to material properties could be
the technique is unsuitable for processing organic materials. achieved by using them.
The production of fullerenes and carbon nanotubes is a During the 1960s, 1970s, and early 1980s there was a
specific subset of gas-phase synthesis techniques. Many gradual expansion as large multinational companies
variations have been explored and patented in the years since established subsidiaries. The real burst in the
they were discovered16. All the techniques essentially involve commercialization of nanoparticle production has occurred
the controlled growth of a nanotube on a catalyst particle over the last ten years or so. One of the main drivers for this
through the cracking of carbon-rich gases such as methane. has been the extraordinary growth in the electronics and
It is possible to make low-purity nanotubes using electric optoelectonics industries. As the technologies have developed
discharge techniques, but this results in wide variations in and functionality has increased, the drive has been to
materials within a batch. Most techniques are increasingly produce smaller and smaller products requiring smaller
focused on the production of either single- or multi-walled components. This has meant that designers are demanding
nanotubes, with significant efforts going into increasing the more from the materials used to construct the devices, which
purity and yields. There are currently no large-scale has led to a search for ways to produce major improvements
production facilities in operation, but a number of companies in performance and the move to nanoscale materials.
in the USA, Japan, and Europe are planning to install In all, there are over 1500 companies involved in
significant production capacity. nanotechnology R&D worldwide1. It is not easy to extract
As can be seen, there are a multitude of different methods from the data which companies are nanomaterials focused
employed to manufacture nanoparticles and carbon but, where the data17-23 is available, one can see this rapid
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Table 2 The primary material product types and primary market focuses of nanomaterials companies17–19.
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Table 3 Estimated global production rates for various nanomaterials and devices, based on international chemical journals and reviews (2003-2004) and
market research (2001). Rates are intended for guidance only, as validated numbers are commercially confidential8.
directed towards investigating nanoscale materials, the value of the market is dependent on the materials used and
ability to make a step-change in performance is being found the actual use so, although catalysts have a much larger
all the time. volume than sunscreens, their values are very similar. The
This is opening up totally new applications and the extreme end of the spectrum is biodetection and labeling
possibility of making products that have been hypothesized materials, where a small amount goes a long way and,
about for many years, such as targeted drug delivery, new although only a few kilos are sold, the price per kilo is many
optoelectronic devices, and smaller, more efficient energy orders of magnitude greater than, for example, CMP
devices. Carbon nanotubes are proving to have some unusual materials.
properties16, such as being able to convert light into electric There is a myriad of applications using nanoparticles either
current30, which could enable an enormous range of new on the market or under development. Table 4 identifies some
applications. This is prompting some companies to gear up to of the key applications.
produce significant quantities of these materials, of the order Considerable effort is being put into developing advanced
of hundreds of tonnes per year31. defence applications for nanomaterials, which are unlikely to
This wealth of potential applications has given rise to reach deployment for quite a few years to come, but which
some widely differing estimates of the overall size of the could have a large impact on commercial applications35-37.
nanotechnology market and of the subsidiary nanomaterials The scope and number of applications38-43 for nanoparticles
market. Nanotechnology as a whole is estimated to have a continues to grow and companies are finding more and more
market of $11 trillion by 2010, with nanomaterials growing uses for these materials.
from $490 million today to $900 million in 2005 and
$11 billion in 201019,32,33. However, the impact of Health, environmental, and ethical
nanomaterials will extend way beyond the immediate value issues
of the materials themselves. One estimate has been made Over the last couple of years, the potential impact of
that nanostructured materials and processes could have an introducing nanotechnologies and nanomaterials into the
impact of over $340 billion by 201034. market has received a greater profile. This has generated
Looking at the major markets for functional nanomaterials much debate, both in the scientific world and the general
today, the largest by volume are automotive catalysts, media.
chemical-mechanical planarization (CMP), magnetic recording The result of this increased interest has been the
media, and sunscreens with 11 500 tonnes, 9 400 tonnes, establishment of a number of working groups to look into the
3 100 tonnes, and 1 500 tonnes, respectively17. However, the health, environmental, and ethical issues surrounding
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Electronics EMI shielding using conducting and Ferrofluids using magnetic materials Chemical-mechanical planarization
magnetic materials alumina, ceria
Electrically conductive plastics Optoelectronics devices such as switches Coatings and joining materials
using rare-earth-doped ceramics for optical fibers based on Si
Light-emitting Si LED nanoparticles for Smaller multilayer capacitors (MLCs)
displays using Ni and Cu nanopowders
Electronic circuits, nonvolatile random Conductive coatings and fabrics using
access memory (NRAM) using Cu, Al rare-earth-doped ceramics
Display technologies including field- Nanoscale magnetic particles for high-
emission devices using conducting density data storage
oxides and carbon nanotubes
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nanotechnology44-46. Even the insurance industry has surface chemistry and how particlescan be dispersed in a
examined the potential impact on its business47. wide variety of media will be key to the adoption of many
One of the major concerns of these studies is the potential materials;
health and environmental risks associated with • Consistency and reliability in volume production –
nanomaterials. Currently there is little information available tolerances on size and composition can be achieved
concerning the risks, but there are data on nanoparticles reliably for simple compounds such as binary oxides and
produced by combustion and smoking. It is also recognized for more complex materials in small batch production, but
that there are already vast numbers of nanoparticles already doing this for the complex materials in volume
present in the air. As the Royal Society report8 observes, manufacturing is not so easy;
“Small size alone is not the critical factor in the toxicity of • Characterization – it is possible to characterize materials
nanoparticles; the overall number and thus the total surface to a great extent. However, many of the techniques are
area (essentially the dose) are also important.” This lack of appropriate for the research lab but not for the production
information requires correction, both while the quantities of environment. Rapid, bulk, and preferably on-line
materials produced are small and to answer the question of techniques are required to monitor properties such as
whether nanomaterials are different to other forms of the particle size distribution;
same material purely through their small size. In addition to • The need to focus in a very broad market – the ability to
recommending further research into the toxicological aspects pick out the applications that will come to market early
of nanomaterials, the report also recommends that chemicals will determine the survival of many nanomaterials
in the form of nanoparticles or nanotubes are treated as new companies in the short term as they start to build
substances and assigned a new Chemical Abstract Service revenues and try to survive while products are developed
(CAS) Registry number. This could have a major impact on and production capability is installed;
the development and adoption of new nanomaterials, so the • How to add and retain value – this will be key to the
implications need to be considered seriously by the longer-term viability of companies as volumes increase
nanomaterials industry. and pressure to reduce prices and hence margins increases.
The approach adopted by many is of securing intellectual
The future for nanoparticles and the property to provide a longer-term income stream;
companies that make them • Health, safety, and environment – the profile of
The use of nanoparticles is set to escalate and the market has nanotechnology has increased in recent years with a focus
the potential to increase dramatically over the next ten on the potential long-term effects of nanotechnology and,
years, as more uses for these materials are developed and more immediately, nanomaterials on people and the
commercialized. environment8,44-51. As with any high-profile technology,
A major impact will be in the medical and pharmaceutical questions will be asked, but some nanomaterials have
markets as new treatments using nanoparticles obtain been with us for many years without causing concern.
licenses for use. But there are many other applications where However, it is very important to the success of this
the time to market is considerably less than the industry that any concerns are addressed. The key aspect
pharmaceutical market, particularly in consumer goods. is: are there any detrimental effects over and above those
However, there are still many challenges for nanomaterials already identified purely from the fact that these materials
companies to overcome before the potential is fully realized. are in the nano form? It is also highly unlikely that
These include: nanomaterials will be used without being incorporated
• How to produce materials in volume commercially at into some other media, such as a composite or liquid.
viable prices – many current techniques cannot scale up Research is underway into the effects of nanomaterials,
sufficiently to produce the cost reductions required to and it is difficult to draw any firm conclusions to date, but
target volume markets; there is evidence that there may be positive benefits from
• How to supply the materials in a form suitable for these types of material both for humans and the
inclusion in manufacturing processes – understanding the environment50,52.
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Conclusion develop faster over the coming years. The challenge for
Nanoparticles and nanomaterials continue to attract a great nanomaterials companies to see this potential come to
deal of attention because of their potential impact on an fruition will be to provide the materials in volume to meet
incredibly wide range of industries and markets. market demands, with the desired quality, in an economic
Consequently, the technology is evolving rapidly and will and safe manner. NT
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