Biomedical applications of nanoparticles made by flame spray pyrolysis

Flame aerosol reactors are the preferred industrial method for producing nanostructured materials such as carbon black, fumed silica, and titania pigments. These reactors enable large-scale, reproducible nanopowder synthesis. The field has been revolutionized by the integration of two-phase atomization nozzles in flame spray pyrolysis (FSP) reactors; these reactors enable the processing of virtually any precursor via liquid dissolution and greatly surpasses the limitations of traditional vapor-based approaches. Most importantly, FSP is no longer a "black box"; recent advances in theory and experiments have provided fundamental insights into particle growth dynamics and enabled the precise control over nanoparticle properties with low batch-to-batch variation. This understanding is crucial for biomedical applications, where reproducibility and functional performance are vital. Here, we review the latest developments in flame-made nanoparticles for biomedical applications, with a focus on FSP reactor engineering, surface property control, and direct integration into medical devices. We discuss the theoretical framework behind reactor design and its impact on material performance. While FSP has demonstrated remarkable versatility for medical nanomaterials, addressing challenges such as good manufacturing practice (GMP) compliance, in vivo safety, and clinical translation will be essential for its widespread adoption in biomedicine. • Flame spray pyrolysis enables scalable, continuous, and reproducible synthesis of nanomaterials for biomedical use. • Reactor design tuning in FSP enables mixed oxides, doped systems, core-shell nanoparticles, and porous coatings. • Case studies show FSP nanomaterials for antibacterial devices, drug delivery, biosensing, and stimuli-responsive systems. • Enclosed FSP with vapor precursors enables coated non-oxides, supporting precise functionalization for biomedical uses. • A safe-by-design framework links FSP processing to toxicity and supports GMP- and QbD-aligned clinical translation.