jats:pThe direct growth of single-walled carbon nanotubes (SWCNTs) with a narrow distribution of diameter or chirality remains elusive despite significant benefits in properties and applications. Nanoparticle catalysts are vital for SWCNT synthesis, but how to precisely manipulate their chemistry, size, concentration, and deposition remains difficult, especially within a continuous production process from the gas phase. Here, we demonstrate the preparation of W6Co7 alloyed nanoparticle catalysts with precisely tunable stoichiometry using electrospray, which remain solid state during SWCNT growth. We also demonstrate continuous production of liquid iron nanoparticles with in-line size selection. With the precise size manipulation of catalysts in the range of 1–5 nm, and a nearly monodisperse distribution (σg < 1.2), an excellent size selection of SWCNTs can be achieved. All of the presented techniques show great potential to facilitate the realization of single-chirality SWCNTs production.</jats:p>