Despite an explosion in nanomaterials discovery, with many potential applications, very few have been commercialised. Barriers lie with scalability, economics and sustainability. Indeed, a raft of ‘highly promising’ higher value nanomaterials have so far failed to meet their promise, or indeed to escape the laboratory. Hence commercial manufacturing of sustainable and scalable high-value nanomaterials remains elusive. Addressing these barriers requires new systems-based and integrative mind-set. It enables parallel and responsive progression of multiple and dependent research strands, according to need, opportunities, and emergent knowledge. This approach sits at odds with the traditional linear view, which focuses initially on the discovery of specific material leads at the laboratory scale, leaving scale-up and commercialisation to be considered as distinctly separate and disconnected concerns. Our integrated approach considers aspects ranging from materials discovery to applications and manufacturing as shown in the schematic. With the example of bioinspired “green” nanosilica product system, this presentation will illustrate how an integrated approach was implemented and how it helped overcome multiple technological challenges. • We will discuss a novel sequential DoE strategy complemented by a variance-based Global Sensitivity Analysis used for materials discovery and resource-efficient process development.4 • The molecular-scale understanding of the materials synthesis was developed by probing the self-assembly and kinetics underpinning their formation. • Simultaneously, we focussed on investigating the mixing mechanisms controlling the synthesis in order to develop a scale-up methodology. From this work, mixing time and conditions were correlated with both the fluidic conditions and the reaction products. • Coupled with this, the economic feasibility and sustainability of the process at industrial scale was estimated, providing key insights into scale-up and commercialisation. Given the “circular” nature of this approach, we will show how key outputs from research in one discipline has provided valuable inputs for others, which have in turn helped enrich the discovery to market journey.