Systematic Design of a Graphene Ink Formulation for Aerosol Jet Printing

Area of Science:

• Materials Science
• Additive Manufacturing
• Nanotechnology

Background:

• Aerosol jet printing (AJP) is a versatile additive manufacturing technique for functional materials.
• Ink formulation challenges limit AJP's potential, with research often prioritizing device demonstration over fundamental process science.

Purpose of the Study:

• To systematically formulate a polymer-stabilized graphene ink for aerosol jet printing.
• To investigate the impact of solvent composition on ink properties and printing outcomes.

Main Methods:

• A four-component solvent mixture (isobutyl acetate, diglyme, dihydrolevoglucosenone, glycerol) was developed.
• Ink properties including dispersion, rheology, wetting, drying, and phase separation were analyzed.
• Printed biochemical sensors were fabricated and tested for pesticide detection.

Main Results:

• The optimized solvent system facilitated efficient atomization and controlled drying, reducing overspray and wetting issues.
• High resolution and electrical conductivity were maintained, overcoming common AJP trade-offs.
• Graphene-based biochemical sensors achieved a 732 nM detection limit for parathion.

Conclusions:

• A rational approach to graphene ink formulation for AJP was established.
• The developed ink is suitable for fabricating high-performance electronic devices.
• This work advances the foundational understanding of AJP ink-material interactions.