Nanocrystalline and nanometer-size fullerene particles have been gener
ated by aerosol routes starting from a solution of mixed fullerene ext
ract in toluene. Nanocrystalline fullerene particles have been produce
d by spray drying, and ultrafine particles have been formed by vapor c
ondensation. Gas-phase particle size distributions were determined wit
h a differential mobility analyzer, and particle morphology and crysta
llinity were studied by scanning and transmission electron microscopie
s. When the processing temperature was increased from 20 to 400 degree
s C, the average particle size was reduced from 140 to 100 nm due to p
article densification. At higher temperatures of 500 and 600 degrees C
, nanometer-size (about 20 nm), spherical fullerene particles were for
med via vapor condensation. Transmission electron microscopy analysis
indicated that a few nanometer-size crystallites were formed already a
t 200 degrees C and the crystallite size was increased to about 10 nm
at 500 degrees C.