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Tuning Printability and Adhesion of a Silver-Based Ink for High-Performance Strain Gauges Manufactured via Direct Ink

Md Alamgir Hossain¹, Gabriela Plautz-Ratkovski¹, Joshua DeGraff²

¹Department of Chemical and Biomedical Engineering, FAMU-FSU College of Engineering, Tallahassee, Florida 32310, United States.

|January 20, 2025

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This study developed high-sensitivity, durable printed strain gauges for structural health monitoring using a novel ink formulation. The new gauges exhibit superior performance and stability for space exploration applications.

Area of Science:

Materials Science
Mechanical Engineering
Aerospace Engineering

Background:

Structural health monitoring (SHM) is crucial for space exploration safety.
Conventional strain gauges lack the sensitivity and durability required for demanding applications.
Existing strain gauges have a low gauge factor (GF ~ 2), limiting their effectiveness.

Purpose of the Study:

To develop highly sensitive, stretchable, and durable printed strain gauges.
To optimize ink formulations for direct ink writing (DIW) of strain gauges.
To enhance the long-term sensing response and reliability of printed strain gauges.

Main Methods:

Formulation of viscoelastic inks using commercial silver ink (CB028) with ethyl cellulose (EC) and polyolefin (PO) additives.

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Systematic rheological characterization including frequency sweep, yield stress, viscoelastic recovery, viscosity, and tack tests.

Application of a viscoelastic window approach to predict optimal ink properties for DIW.

Fabrication of strain gauges via DIW and testing using a three-point bending configuration.

Main Results:

An optimized ink formulation (90% CB028, 5% EC, 5% PO) demonstrated enhanced elastic properties, adhesion, and peel strength.
The formulated ink achieved high tack (129 mN/mm²) and peel strength (23.3 kJ/mm²), ideal for DIW.
Printed strain gauges exhibited high gauge factors (GF ~ 106) with stable sensing responses over 300 strain cycles.
Microstructural analysis revealed minimal crack formation, ensuring stable performance.

Conclusions:

The study successfully demonstrated the feasibility of creating high-performance printed strain gauges with superior sensitivity and durability.
The developed ink formulation and DIW process offer a promising solution for advanced structural health monitoring in aerospace and other critical applications.
This research paves the way for next-generation printed electronic sensors with enhanced mechanical and sensing capabilities.