Engineering Mesoporous Silica Hosts for Ultrasmall ZnO Nanoparticles: A Dendritic Polymer-Assisted Strategy Towards Sustainable, Safe, and Effective Antibacterial Systems

In response to the urgent need for sustainable antibacterial solutions against antibiotic-resistant pathogens, this study presents a facile dendritic polymer-assisted approach for synthesizing highly active ZnO/mesoporous silica nanocomposites (SBA-15, SBA-16, KIT-6, MSU-X). Two hyperbranched polymers—polyethyleneimine (PEI) and carboxy-methylated polyethyleneimine (Trilon-P, TrP)—were employed as templating and metal-trapping agents. The influence of pore geometry, polymer functionality, and polymer-loading method (wet or dry impregnation) on ZnO nanoparticle (NP) formation was systematically examined. All nanocomposites exhibited high structural homogeneity, incorporating ultrasmall or amorphous ZnO NPs (1–10 nm) even at 8 wt.% Zn loading. Zn uptake was strongly dependent on polymer end groups, while the spatial distribution of ZnO NPs was dictated by the silica host structure. Antibacterial assays against Staphylococcus aureus revealed remarkable activity, particularly for ZnO/SBA-15_PEI, ZnO/SBA-16_PEI, and ZnO/MSU-X_TrP nanocomposites, with minimum inhibitory concentrations of 1–2.5 μg mL−1 Zn and over 90% mammalian cell viability. Life Cycle Assessment identified energy use as the main environmental factor, with ZnO/SBA-15_PEI_WI displaying the lowest impact. Overall, the interplay between silica pore architecture, polymer type, and impregnation method governs ZnO accessibility and bioactivity, establishing a versatile strategy for designing next-generation ZnO/SiO2 nanocomposites with tunable antibacterial efficacy and minimal cytotoxic and environmental footprint.