The availability of nanoparticles in a form suitable for industrial processes remains a key limitation for the deployment of nanocomposite coatings. This work presents the scaling of high-energy ball milling (HEBM) as a combined route for nanoparticle synthesis, size refinement, and direct predispersion in liquid media, enabling the production of concentrated, ready-to-use nanoparticle masterbatches.

High-energy ball milling was adapted from laboratory to pilot scale to process ceramic nanoparticle systems, with a primary focus on SiC and Al₂O₃. The approach allows simultaneous particle size reduction and deagglomeration while promoting effective wetting and stabilisation in liquid carriers. The resulting masterbatches exhibit narrow particle size distributions, reduced agglomeration tendency, and long-term colloidal stability, enabling straightforward dosing into downstream processes without additional dispersion steps or handling of dry powders.

In addition to the demonstrated systems, other carbide-based nanoparticles, including TiC and B₄C, showed strong potential when processed via the same methodology. Their intrinsic mechanical properties indicate suitability for advanced nanocomposite applications.

The scaling of HEBM for liquid predispersion provides a robust and versatile pathway for supplying industrially relevant nanoparticle masterbatches. This contribution highlights how process engineering of nanoparticle production and formulation can bridge the gap between nanomaterial development and practical industrial use.