Safer formulation concept for flame-generated engineered nanomaterials

The likely success or failure of the nanotechnology industry depends on the environmental health and safety of engineered nanomaterials (ENMs). While efforts toward engineering safer ENMs are sparse, such efforts are considered crucial to the sustainability of the nanotech industry. A promising approach in this regard is to coat potentially toxic nanomaterials with a biologically inert layer of amorphous SiO₂. Core-shell particles exhibit the surface properties of their amorphous SiO₂ shell while maintaining specific functional properties of their core material. A major challenge in the development of functional core-shell particles is the design of scalable high-yield processes that can meet large-scale industrial demand. Here, we present a safer formulation concept for flame-generated ENMs based on a one-step, in flight SiO₂ encapsulation process, which was recently introduced by the authors as a means for a scalable manufacturing of SiO ₂-coated ENMs. First, the versatility of the SiO₂-coating process is demonstrated by applying it to four ENMs (CeO_2, ZnO, Fe₂O₃, Ag) marked by their prevalence in consumer products as well as their range in toxicity. The ENM-dependent coating fundamentals are assessed, and process parameters are optimized for each ENM investigated. The effects of the SiO₂-coating on core material structure, composition, and morphology, as well as the coating efficiency on each nanostructured material, are evaluated using state-of-the-art analytical methods (XRD, N ₂ adsorption, TEM, XPS, isopropanol chemisorption). Finally, the biological interactions of SiO₂-coated vs uncoated ENMs are evaluated using cellular bioassays, providing valuable evidence for reduced toxicity for the SiO₂-coated ENMs. Results indicate that the proposed "safer by design" concept bears great promise for scaled-up application in industry in order to reduce the toxicological profile of ENMs for certain applications.