Current challenges in the areas of health care, environmental protection, and, especially, the mobility transition have introduced a wide range of applications for specialized high-performance materials. Hence, this paper presents a novel approach for designing materials with flame spray pyrolysis on a lab scale and transferring the synthesis to the pulsation reactor for mass production while preserving the advantageous material properties of small particle sizes and highly specific surface areas. A proof of concept is delivered for zirconia and silica via empirical studies. Furthermore, an interdisciplinary approach is introduced to model the processes in a pulsation reactor in general and for single material particles specifically. Finally, facilities for laboratory investigations and pulsation reactor testing in an industrial environment are presented.

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