Plasma Based Ultrafine Particle Synthesis Process (PSP), a new technique to produce nanomaterials has been developed. This technique uses:

• An industrial plasma spray system to produce nanomaterials under atmospheric conditions

• A parallel plate electrostatic precipitator to collect the nanomaterials

Nanomaterials, including alumina, zirconia and YSZ, have been produced by this process. PSP-produced materials have characteristics similar to nanomaterials produced by other techniques. The plasma synthesis process has many advantages such as:

• PSP is a simple process to install and operate - many commercial systems which are already in place within industry can be adapted for a value-added process and/or product

• PSP is a single step process to produce both nanomaterial powders and deposits. No post-spray calcination or heat treatment is required

• PSP is an economical process - it does not use costly equipment such as high power lasers and ultra high vacuum systems

• PSP is a versatile and flexible process - there is the capability to synthesis complex composite materials with tailored compositions.