Selective Growth of Graphene-Confined Inkjet-Printed Sn Nanoparticles on Plastic Using Intense Pulsed Light Annealing

Printing graphene-based nanomaterials on flexible substrates has become a burgeoning platform for next-generation technologies. Combining graphene and nanoparticles to create hybrid nanomaterials has been proven to boost device performance, thanks to their complementary physical and chemical properties. However, high growth temperatures and long processing times are often required to produce high-quality graphene-based nanocomposites. For the first time, we report a novel scalable approach for additive manufacturing of Sn patterns on polymer foil and their selective conversion into nanocomposite films under atmospheric conditions. A combination of inkjet printing and intense flashlight irradiation techniques is studied. Light pulses that are selectively absorbed by the printed Sn patterns cause a temperature of over 1000 °C to be reached locally in a split second without damaging the underlying polymer foil. The top surface of the polymer foil at the interface with printed Sn becomes locally graphitized and acts as a carbon source, transforming printed Sn into Sn@graphene (Sn@G) core-shell patterns. Our results revealed a decrease in electrical sheet resistance, with an optimal value (R_s = 72 ± 2 Ω/sq) reached when light pulses with an energy density of 12.8 J/cm² were applied. These graphene-protected Sn nanoparticle patterns exhibit excellent resistance against air oxidation for months. Finally, we demonstrate the implementation of Sn@G patterns as electrodes for Li-ion microbatteries (LIBs) and triboelectric nanogenerators (TENGs), showing remarkable performance. This work offers new insight into the development of a versatile, eco-friendly, and cost-effective technique for producing well-defined patterns of graphene-based nanomaterials directly on a flexible substrate using different light-absorbing nanoparticles and carbon sources.