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As a low‐cost alternative to noble metals, Cu plays an important role in industrial catalysis, such as water‐gas shift reaction, methanol or ethanol oxidation, hydrogenation of oils, CO oxidation, among many others. An important step in optimizing Cu catalyst performance is control of nanoparticles size, distribution, and the interface with the support. While proton conducting perovskites can enhance the metal catalytic activity when acting as the support, there has been limited investigation of in situ growth of Cu metal nanoparticles from the proton conductors and its catalytic performance. Here, Cu nanoparticles are tracked exsolved from an A‐site‐deficient proton‐conducting barium cerate‐zirconate using scanning electron microscopy, revealing a continuous phase change during exsolution as a function of reduction temperature. Combined with the phase diagram and cell parameter change during reduction, a new exsolution mechanism is proposed for the first time which provides insight into tailoring metal particles interfaces at proton conducting oxide surfaces. Furthermore, the catalytic behavior in the CO oxidation reaction is explored and, it is observed that these new nanostructures can rival state of the art catalysts over long term operation. [ABSTRACT FROM AUTHOR]

High‐performance nanoparticle platforms can drive catalysis progress to new horizons, delivering environmental and energy targets. Nanoparticle exsolution offers unprecedented opportunities that are limited by current demanding process conditions. Unraveling new exsolution pathways, particularly at low‐temperatures, represents an important milestone that will enable improved sustainable synthetic route, more control of catalysis microstructure as well as new application opportunities. Herein it is demonstrated that plasma direct exsolution at room temperature represents just such a step change in the synthesis. Moreover, the factors that most affect the exsolution process are identified. It is shown that the surface defects produced initiate exsolution under a brief ion bombardment of an argon low‐pressure and low‐temperature plasma. This results in controlled nanoparticles with diameters ≈19–22 nm with very high number densities thus creating a highly active catalytic material for CO oxidation which rivals traditionally created exsolved samples. [ABSTRACT FROM AUTHOR]