The use of a guide-tube and bluff-body with an advanced atmospheric pressure plasma source is investigated for the low-temperature synthesis of single-crystalline high-density plasma polymerized pyrrole (pPPy) nano-materials on glass and flexible substrates. Three process parameters, including the position of the bluff-body, Ar gas flow rate, and remoteness of the substrate from the intense and broadened plasma, are varied and examined in detail. Plus, for an in-depth understanding of the flow structure development with the guide-tube and bluff-body, various numerical simulations are also conducted using the same geometric conditions as the experiments. As a result, depending on both the position of the bluff-body and the Ar gas flow rate, an intense and broadened plasma as a glow-like discharge was produced in a large area. The production of the glow-like discharge played a significant role in increasing the plasma energy required for full cracking of the monomers in the nucleation region. Furthermore, a remote growth condition was another critical process parameter for minimizing the etching and thermal damage during the plasma polymerization, resulting in single- and poly-crystalline pPPy nanoparticles at a low temperature with the proposed atmospheric pressure plasma jet device.

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