Nanostructured ZnO coatings as antiviral surfaces: Influence of synthesis methodology on photocatalytic efficiency

The development of antiviral coatings is crucial for mitigating pathogen transmission. This study evaluates the influence of fabrication methods on the structural, optical, and antiviral properties of nanostructured (NSs) ZnO thin-film coatings for MS2 bacteriophage inactivation under ambient white light (~1000 lux). The quality and morphology of ZnO nanostructures prepared via solution-based methods (sol-gel and hydrothermal) and aerosol-assisted chemical vapour deposition (AACVD) were compared. Structural and optical analyses revealed that AACVD produced highly crystalline, homogeneous ZnO film coatings with well-oriented [001] growth, while solution-based methods resulted in partial amorphous characteristics and bandgap blue shift due to carbon contamination. Antiviral tests showed that AACVD ZnO film coatings achieved a 4-log reduction (99.99%) in MS2 infectivity within 2 h, outperforming the 2-log reduction achieved by solution-based coatings. These results underscore AACVD as a scalable and efficient method for fabricating high-performance ZnO-based antiviral coatings. Influence of fabrication methods on the antiviral properties of nanostructured ZnO thin-film coatings. • Evaluation of impact of synthesis on zinc oxide coatings for antiviral applications. • Aerosol-based deposition of films exhibited enhanced crystallinity and performance. • Aerosol-deposited films achieved 99.99% MS2 virus inactivation under white light. • Carbon contamination in solution-based methods affected optical properties. • Aerosol-assisted CVD is an efficient method to prepare high-performance antiviral coatings.