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Updated: Oct 10, 2025

Hybrid Printing for the Fabrication of Smart Sensors
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3D Electrochemical Sensor and Microstructuration Using Aerosol Jet Printing.

Tiziano Fapanni1, Emilio Sardini1, Mauro Serpelloni1

  • 1Department of Information Engineering, University of Brescia, 25123 Brescia, Italy.

Sensors (Basel, Switzerland)
|December 10, 2021
PubMed
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This study introduces a novel microstructuration technique using aerosol jet printing (AJP) to significantly enhance electrochemical sensor sensitivity. The innovative fabrication process boosts electrode active surface area, leading to a 2.3-fold increase in sensor performance.

Area of Science:

  • Materials Science
  • Electrochemistry
  • Additive Manufacturing

Background:

  • Electrochemical sensors are crucial for various applications, but their performance is limited by metrological characteristics and fabrication processes.
  • Improving sensitivity and reusability are key research goals for advanced electrochemical sensing.

Purpose of the Study:

  • To demonstrate an innovative microstructuration technique for enhancing electrochemical sensor sensitivity.
  • To increase the active electrode surface area using aerosol jet printing (AJP).

Main Methods:

  • Utilized aerosol jet printing (AJP), an additive manufacturing technique, for non-contact deposition of functional inks.
  • Created 3D printed microstructures (lines and grids) to expand the electrode's active surface area.
Keywords:
3D microstructurationaerosol jet printingelectrochemical sensorsprinted electronicsvoltametric sensors

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  • Evaluated sensor sensitivity using electrochemical detection of ferro/ferri-cyanide.
  • Main Results:

    • Achieved up to a 130% increase in active surface area without altering substrate footprint.
    • Demonstrated an average 2.3-fold increase in sensitivity for microstructured electrodes compared to bare ones.
    • Confirmed a linear correlation between increased surface area and enhanced sensitivity.

    Conclusions:

    • The proposed microstructuration technique via AJP is a flexible and effective method for boosting electrochemical sensor sensitivity.
    • This mask-free, scalable fabrication process is suitable for diverse applications requiring high-performance sensors.