Carbon nanotubes (CNTs) are nanomaterials that have attracted great research interest because of their unique properties and promising applications. The controllable synthesis of CNTs is a precondition for their broad application. In this review, we consider nanoscale process engineering and assess recent progress in the mass production of ultra-long, inexpensive CNTs with good alignment as well as tunability in wall number and diameter for fundamental and engineering science applications across multiple scales. Cutting-edge nanoscale process engineering research in the areas of physics, chemistry, materials, engineering, ecology, and social science will allow us to obtain high added value and multi-functional advanced CNTs. The synthesis of CNTs with controllable chirality, good-alignment, and predetermined sizes and lengths still presents great challenges. Through multidisciplinary scientific research, advanced CNT-based materials will promote the development of a sustainable society. According to the wall number of a CNT, it can be classified as a SWCNT, double-walled CNT (DWCNT), triple-walled CNT (TWCNT), or multi-walled CNT (MWCNT). Because of the covalent sp 2 bonds between individual carbon atoms, a nanotube can have a Young's modulus between 1.2-5.5 TPa, a tensile strength about a hundred times greater than that of steel, and can tolerate large strains before mechanical failure. A CNT can be a metal, semiconductor, or small-gap semiconductor. The state of the CNT depends heavily on the (m, n) indices, and, therefore, on the diameter and chirality. CNTs also possess tunable surfaces characteristics, well-defined hollow interiors, and high biocompatibility with living systems. Based on these properties, many potential applications, including both large-volume applications (such as conductive, electromagnetic, microwave absorbing, high-strength composites; super capacitor, or battery electrodes; catalyst and catalyst support; field emission displays; and transparent conducting films) and limited-volume applications (such as scanning probe tips; drug delivery systems; electronic devices; sensors; and actuators) have been proposed [2]. Controllable mass production of CNTs with the desired structures and properties is essential for future applications. In the past 20 years, arc discharge, laser ablation, and chemical vapor deposition (CVD) methods have been developed to produce CNTs in sizeable quantities. In CVD methods, the catalytic decomposition of a carbon feedstock into carbon and hydrogen atoms is initiated on an active catalyst surface, where the tubular CNTs grown. CVD growth can be achieved under mild conditions (such as normal pressure