Next-generation materials and devices by combustion processes

Combustion-based processes constitute a versatile class of thermally driven synthesis routes for the rapid, scalable production of advanced materials. These include flame aerosol synthesis, combustion synthesis, and solution combustion synthesis. Despite differences in implementation, these methods share common characteristics: self-sustaining exothermic processes, rapid reaction kinetics, high localized temperatures, and heating rate. These enable energy-efficient processing of a wide variety of materials and access to metastable and non-equilibrium phases. This review article summarizes recent advances in combustion-based synthesis methods for producing advanced materials and devices, with emphasis on reaction mechanisms, process–structure relationships, and the control of composition, defects, and microstructure. Key material systems are discussed, including nanostructured oxides, ultra-high-temperature ceramics, high-entropy materials, and MAX phases, thermoelectrics, along with emerging applications in thin films and device integration. Particular attention is given to the transition from empirical optimization toward predictive synthesis, supported by developments for in situ diagnostics, multiscale modeling, and data-driven approaches. Challenges related to reproducibility, scalability, and precise control of non-equilibrium processes are critically assessed. The integration of combustion-based methods with advanced manufacturing and continuous processing is also considered.