Open Access

The rising threat from infectious pathogens poses an ever-growing challenge. Metal-based nanomaterials have gained a great deal of attention as active components in antimicrobial coatings. Here, we report on the development of readily deployable, sprayable antimicrobial surface coatings for high-touch stainless steel surfaces that are ubiquitous in many healthcare facilities to combat the spread of pathogens. We synthesized mesoporous silica nanoparticles (MSNs) with different surface functional groups, namely, amine (MSN-NH2), carboxy (MSN-COOH), and thiol groups (MSN-SH). These were chosen specifically due to their high affinity to copper and silver ions, which were used as antimicrobial payloads and could be incorporated into the mesoporous structure through favorable host−guest interactions, allowing us to find the most favorable combinations to achieve antimicrobial efficacy against various microbes on dry or semidry high-touch surfaces. The antimicrobial MSNs were firmly immobilized on stainless steel through a simple two-step spray-coating process. First, the stainless steel surfaces are primed with sprayable polyelectrolyte solutions acting as adhesion layers, and then, the loaded nanoparticle dispersions are spray-coated on top. The employed polyelectrolytes were selected and functionalized specifically to adhere well to stainless steel substrates while at the same time being complementary to the MSN surface groups to enhance the adhesion, wettability, homogeneity, and stability of the coatings. The antimicrobial properties of the nanoparticle suspension and the coatings were tested against three commonly found pathogenic bacteria, Staphylococcus aureus, Pseudomonas aeruginosa, and Escherichia coli, as well as a fungal pathogen, Candida albicans. Especially MSN-SH loaded with silver ions showed excellent antimicrobial efficacy against all tested pathogens under application-relevant, (semi)dry conditions. The findings obtained here facilitate our understanding of the correlation between the surface properties, payloads, and antimicrobial activity and show a new pathway toward simple and easily deployable solutions to combat the spread of pathogens with the help of sprayable antimicrobial surface coatings.

Functional films with tailored interfacial properties play a pivotal role for the development of next generation surface coatings, particularly in healthcare-related environments. In this contribution, we present a facile spray-coating method for the creation of antimicrobial thin films on high-touch surfaces using mesoporous silica nanoparticles (MSNs) that were specifically functionalized to enable strong adhesion and sustained release of metal-based antimicrobial agents. The process is scalable and addresses key challenges in adhesion control, film homogeneity, and long-term antimicrobial function against a large range of key pathogens responsible for nosocomial infections. Three distinct types of MSNs – bearing amine (MSN-NH₂), carboxy (MSN-COOH), and thiol (MSN-SH) surface groups – were synthesized to optimize both metal ion loading and interactions with polyelectrolyte-based adhesion layers. These surface modifications not only provide chemical handles for Cu²⁺ and Ag⁺ ion coordination but also modulate nanoparticle-substrate interactions and dispersion behavior during film formation. The coating architecture consists of a two-step process: first, spray deposition of polyelectrolyte primers that anchor strongly to stainless steel substrates; second, a nanoparticle layer that bonds electrostatically and chemically to the primer, forming robust films with great surface coverage. The films were characterized to assess structural integrity, adhesion, and functional performance. Transmission electron microscopy (TEM) and N₂ sorption analysis confirmed the mesoporous structure. ATR-FTIR and zeta potential measurements validated surface functionalization and colloidal stability. Environmental SEM revealed conformal coating across the stainless-steel surfaces with uniform nanoparticle distribution. The coating's adhesion strength was maintained through mechanical wiping and simulated wear and abrasion tests, demonstrating film durability relevant in real-world use scenarios. Antimicrobial testing under semi-dry, application-relevant conditions showed excellent performance for Ag⁺-loaded MSN-SH films, inhibiting growth of Staphylococcus aureus, Pseudomonas aeruginosa, Escherichia coli, and Candida albicans. These results highlight the synergistic role of surface chemistry, metal ion loading, and film-substrate adhesion in creating effective and wear-resistant functional coatings. Moreover, these films do not show any cytotoxic properties towards Human Dermal Fibroblasts (HDF). This study contributes new insights into the design of multifunctional films where adhesion, surface functionality, and scalable processing are co-optimized for enhanced performance and shows how combining tailored surface chemistry and wide-ranging antimicrobial activity brings together smart material design for practical and safe use.