Roll-to-Roll Laser-Printed Graphene-Graphitic Carbon Electrodes for High-Performance Supercapacitors

Ink-based additive manufacturing for electrochemical applications

Additive manufacturing (AM), commonly known as three-dimensional (3D) printing, has drawn substantial attention in recent decades due to its efficiency and precise control in part fabrication. The limitations of conventional fabrication processes, especially regarding geometry complexity, supply chain, and environmental impact, have prompted the exploration of diverse AM technologies in electrochemistry. Especially, three ink-based AM techniques, binder jet printing (BJP), direct ink writing (DIW), and Inkjet Printing (IJP), have been extensively applied by numerous research teams to produce electrodes, catalyst scaffolds, supercapacitors, batteries, etc. BJP's versatility in utilizing a wide range of materials as powder feedstock promotes its potential for various electrode and battery applications. DIW and IJP stand out for their ability to handle multi-material manufacturing tasks and deliver high printing resolution. To capture recent advancements in this field, we present a comprehensive review of the applications of BJP, DIW, and IJP techniques in fabricating electrochemical devices and components. This review intends to provide an overview of the process-structure-property relationship in electrochemical materials and components across diverse applications manufactured using AM techniques. We delve into how the significantly improved design freedom over the structure offered by these ink-based AM techniques highlights the performance of electrochemical products. Moreover, we highlight their advantages in terms of material compatibility, geometry control, and cost-effectiveness. In specific cases, we also compare the performance of electrochemical components fabricated using AM and conventional manufacturing methods. Finally, we conclude this review article by offering some insights into the future development in this research field.

Recent advances in polyaniline-based micro-supercapacitors

The rapid development of the Internet of Things (IoTs) and proliferation of wearable electronics have significantly stimulated the pursuit of distributed power supply systems that are small and light. Accordingly, micro-supercapacitors (MSCs) have recently attracted tremendous research interest due to their high power density, good energy density, long cycling life, and rapid charge/discharge rate delivered in a limited volume and area. As an emerging class of electrochemical energy storage devices, MSCs using polyaniline (PANI) electrodes are envisaged to bridge the gap between carbonaceous MSCs and micro-batteries, leading to a high power density together with improved energy density. However, despite the intensive development of PANI-based MSCs in the past few decades, a comprehensive review focusing on the chemical properties and synthesis of PANI, working mechanisms, design principles, and electrochemical performances of MSCs is lacking. Thus, herein, we summarize the recent advances in PANI-based MSCs using a wide range of electrode materials. Firstly, the fundamentals of MSCs are outlined including their working principle, device design, fabrication technology, and performance metrics. Then, the working principle and synthesis methods of PANI are discussed. Afterward, MSCs based on various PANI materials including pure PANI, PANI hydrogel, and PANI composites are discussed in detail. Lastly, concluding remarks and perspectives on their future development are presented. This review can present new ideas and give rise to new opportunities for the design of high-performance miniaturized PANI-based MSCs that underpin the sustainable prosperity of the approaching IoTs era.

Sand-Milling Fabrication of Screen-Printable Graphene Composite Inks for High-Performance Planar Micro-Supercapacitors

Rational engineering and simplified production of printable graphene inks are essential for building high-energy and flexible graphene micro-supercapacitors (MSCs). However, few graphene-based MSCs show impressive areal capacitance and energy density, especially based on additive-manufacturing, cost-effective, and printable inks. Herein, a new-style and solution-processable graphene composite ink is ingeniously formulated for scalable screen printing MSCs. More importantly, the as-formulated inks consist of interwoven two-dimensional graphene and activated carbon nanofillers, which are delaminated by one-step sand-milling turbulent flow exfoliation. Notably, embedding the activated carbon nanoplatelets into graphene layers drastically boosts the electrochemical performance of screen-printed micro-supercapacitors (denoted as Gr/AC-MSCs), such as an outstanding areal capacitance of 12.5 mF cm^-2 (about 20 times than pure graphene). The maximum energy density, maximum power density, and exceptional cyclability are 1.07 μW h cm^-2, 0.004 mW cm^-2, and 88.1% after 5000 cycles, respectively. As such, the as-printed MSCs on paper display high resolution and pronounced energy-storage performance. Furthermore, the packaged and optimized Gr/AC-MSCs showcase remarkable mechanical flexibility even under highly folded and excellent water resistance, maintaining 91.8% capacitance retention after being washed for 90 min. The versatile methodology highlights the promise of graphene and analogous 2D nanosheet functional inks for scalable fabrication of flexible energy-storage devices.

Laser Fabrication of Graphene-Based Flexible Electronics

Recent years have witnessed the rise of graphene and its applications in various electronic devices. Specifically, featuring excellent flexibility, transparency, conductivity, and mechanical robustness, graphene has emerged as a versatile material for flexible electronics. In the past decade, facilitated by various laser processing technologies, including the laser-treatment-induced photoreduction of graphene oxides, flexible patterning, hierarchical structuring, heteroatom doping, controllable thinning, etching, and shock of graphene, along with laser-induced graphene on polyimide, graphene has found broad applications in a wide range of electronic devices, such as power generators, supercapacitors, optoelectronic devices, sensors, and actuators. Here, the recent advancements in the laser fabrication of graphene-based flexible electronic devices are comprehensively summarized. The various laser fabrication technologies that have been employed for the preparation, processing, and modification of graphene and its derivatives are reviewed. A thorough overview of typical laser-enabled flexible electronic devices that are based on various graphene sources is presented. With the rapid progress that has been made in the research on graphene preparation methodologies and laser micronanofabrication technologies, graphene-based electronics may soon undergo fast development.

Further Thermal Reduction of Reduced Graphene Oxide Aerogel with Excellent Rate Performance for Supercapacitors

Preparation of pure three-dimensional graphene (3DG) with high rate performance for supercapacitors is critical for fast rate charge/discharge. Here, 3DG was prepared via thermal annealing of freeze-dried reduced graphene oxide (RGO) hydrogel under inert gas protection. The formed 3DG as an electrode material for supercapacitors revealed a specific capacitance of 115 F·g−1 at a current density of 1 A·g−1, and a high capacitance retention of 70% as current density increased to 40 A·g−1. The excellent rate capability was mainly attributed to the reserved porous structure and higher electrical conductivity for 3DG after thermal reduction than its RGO hydrogel precursor.

Printed Graphene Electrochemical Biosensors Fabricated by Inkjet Maskless Lithography for Rapid and Sensitive Detection of Organophosphates

Solution phase printing of graphene-based electrodes has recently become an attractive low-cost, scalable manufacturing technique to create in-field electrochemical biosensors. Here, we report a graphene-based electrode developed via inkjet maskless lithography (IML) for the direct and rapid monitoring of triple-O linked phosphonate organophosphates (OPs); these constitute the active compounds found in chemical warfare agents and pesticides that exhibit acute toxicity as well as long-term pollution to soils and waterways. The IML-printed graphene electrode is nano/microstructured with a 1000 mW benchtop laser engraver and electrochemically deposited platinum nanoparticles (dia. ∼25 nm) to improve its electrical conductivity (sheet resistance decreased from ∼10 000 to 100 Ω/sq), surface area, and electroactive nature for subsequent enzyme functionalization and biosensing. The enzyme phosphotriesterase (PTE) was conjugated to the electrode surface via glutaraldehyde cross-linking. The resulting biosensor was able to rapidly measure (5 s response time) the insecticide paraoxon (a model OP) with a low detection limit (3 nM), and high sensitivity (370 nA/μM) with negligible interference from similar nerve agents. Moreover, the biosensor exhibited high reusability (average of 0.3% decrease in sensitivity per sensing event), stability (90% anodic current signal retention over 1000 s), longevity (70% retained sensitivity after 8 weeks), and the ability to selectively sense OP in actual soil and water samples. Hence, this work presents a scalable printed graphene manufacturing technique that can be used to create OP biosensors that are suitable for in-field applications as well as, more generally, for low-cost biosensor test strips that could be incorporated into wearable or disposable sensing paradigms.