Scalable Nanomanufacturing of Antibacterial Surface Coatings: From Nanomaterial Design to Clinical and Industrial Translation

Healthcare-associated infections and rising antimicrobial resistance have driven sustained interest in antibacterial surface engineering as a complement to systemic treatment and terminal disinfection. Nanomaterials, including metal/metal-oxide nanoparticles, iodine/iodophor systems, chitosan composites, and core–shell architectures, offer distinct antibacterial mechanisms and emerging routes to scalable manufacturing. This review synthesizes the literature, deliberately weighting coverage toward manufacturing scalability, mechanical durability, and regulatory translation rather than materials chemistry alone. Using a structured critical-appraisal approach, methodologically pivotal studies are evaluated narratively, while the broader literature is categorized in comprehensive appraisal tables mapping designs, key results, and limitations. Targeted case studies on orthopedic implants and catheters are also examined in depth to expose localized translational bottlenecks. The overall assessment of this work is that while antibacterial nanomaterial chemistry is mature and well characterized across several platforms, scalable deposition methods, standardized durability/retention-of-efficacy testing, and nanomaterial-specific regulatory guidance remain the primary rate-limiting factors in wider clinical and industrial adoption.