Boosting nanoparticle yield: enhanced atom-to-nanoparticle conversion in gas aggregation

Nanoparticles are atomic aggregates with diameters around 10 nm and are highly valued for their unique properties and broad technological applications. Their synthesis via physical methods offers key advantages over chemical methods, including high purity, precise size control, and material versatility, whilst also being environmentally friendly. A current disadvantage of physical synthesis is that they typically suffer from low production yields and inefficient atom-to-nanoparticle conversion. This paper describes the mechanisms of nanoparticle growth and presents a strategy to enhance their production in gas-aggregation systems. The approach leverages pulsed magnetron sputtering, where atoms serve as building blocks for nanoparticle formation. By optimizing pulse duration and repetition frequency, this paper shows significant improvement in atom-to-nanoparticle conversion demonstrating improved nanoparticle production by an order of magnitude without increasing the amount of sputtered material or overall energy consumption. This advancement paves the way for more cost-effective and scalable nanoparticle manufacturing.