Low-Cost Inkjet Printing Technology for the Rapid Prototyping of Transducers

Recent Advances in Patterning Strategies for Full-Color Perovskite Light-Emitting Diodes

Metal halide perovskites have emerged as promising light-emitting materials for next-generation displays owing to their remarkable material characteristics including broad color tunability, pure color emission with remarkably narrow bandwidths, high quantum yield, and solution processability. Despite recent advances have pushed the luminance efficiency of monochromic perovskite light-emitting diodes (PeLEDs) to their theoretical limits, their current fabrication using the spin-coating process poses limitations for fabrication of full-color displays. To integrate PeLEDs into full-color display panels, it is crucial to pattern red-green-blue (RGB) perovskite pixels, while mitigating issues such as cross-contamination and reductions in luminous efficiency. Herein, we present state-of-the-art patterning technologies for the development of full-color PeLEDs. First, we highlight recent advances in the development of efficient PeLEDs. Second, we discuss various patterning techniques of MPHs (i.e., photolithography, inkjet printing, electron beam lithography and laser-assisted lithography, electrohydrodynamic jet printing, thermal evaporation, and transfer printing) for fabrication of RGB pixelated displays. These patterning techniques can be classified into two distinct approaches: in situ crystallization patterning using perovskite precursors and patterning of colloidal perovskite nanocrystals. This review highlights advancements and limitations in patterning techniques for PeLEDs, paving the way for integrating PeLEDs into full-color panels.

Printing MEMS: Application of Inkjet Techniques to the Manufacturing of Inertial Accelerometers

In the last few years, the manufacturing of microelectromechanical systems (MEMS) by means of innovative tridimensional and bidimensional printing technologies has significantly catalyzed the attention of researchers. Inkjet material deposition, in particular, can become a key enabling technology for the production of polymer-based inertial sensors characterized by low cost, high manufacturing scalability and superior sensitivity. In this paper, a fully inkjet-printed polymeric accelerometer is proposed, and its manufacturing steps are described. The manufacturing challenges connected with the inkjet deposition of SU-8 as a structural material are identified and addressed, resulting in the production of a functional spring-mass sensor. A step-crosslinking process allows optimization of the final shape of the device and limits defects typical of inkjet printing. The resulting device is characterized from a morphological point of view, and its functionality is assessed in performing optical readout. The acceleration range of the optimized device is 0-0.7 g, its resolution is 2 × 10-3 g and its sensitivity is 6745 nm/g. In general, the work demonstrates the feasibility of polymeric accelerometer production via inkjet printing, and these characteristic parameters demonstrate their potential applicability in a broad range of uses requiring highly accurate acceleration measurements over small displacements.

Microwave Resonators for Wearable Sensors Design: A Systematic Review

The field of flexible electronics is undergoing an exponential evolution due to the demand of the industry for wearable devices, wireless communication devices and networks, healthcare sensing devices and the technology around the Internet of Things (IoT) framework. E-tex tiles are attracting attention from within the healthcare areas, amongst others, for providing the possibility of developing continuous patient monitoring solutions and customized devices to accommodate each patient's specific needs. This review paper summarizes multiple approaches investigated in the literature for wearable/flexible resonators working as antenna-based systems, sensors and filters with special attention paid to the integration to flexible materials, especially textiles. This review manuscript provides a general overview of the flexible resonators' advantages and drawbacks, materials, fabrication techniques and processes and applications. Finally, the main challenges and future prospects of wearable resonators are discussed.

Ramie Fabric Treated with Carboxymethylcellulose and Laser Engraved for Strain and Humidity Sensing

Wearable fabric sensors have attracted enormous attention due to their huge potential in human health and activity monitoring, human-machine interaction and the Internet of Things (IoT). Among natural fabrics, bast fabric has the advantage of high strength, good resilience and excellent permeability. Laser engraving, as a high throughput, patternable and mask-free method, was demonstrated to fabricate fabric sensors. In this work, we developed a simplified, cost-effective and environmentally friendly method for engraving ramie fabric (a kind of bast fabric) directly by laser under an ambient atmosphere to prepare strain and humidity sensors. We used carboxymethylcellulose (CMC) to pretreat ramie fabric before laser engraving and gained laser-carbonized ramie fabrics (LCRF) with high conductivity (65 Ω sq^-1) and good permeability. The strain and humidity sensors had high sensitivity and good flexibility, which can be used for human health and activity monitoring.

Assessing the Relationships between Interdigital Geometry Quality and Inkjet Printing Parameters

Drop on demand (DoD) inkjet printing is a high precision, non-contact, and maskless additive manufacturing technique employed in producing high-precision micrometer-scaled geometries allowing free design manufacturing for flexible devices and printed electronics. A lot of studies exist regarding the ink droplet delivery from the nozzle to the substrate and the jet fluid dynamics, but the literature lacks systematic approaches dealing with the relationship between process parameters and geometrical outcome. This study investigates the influence of the main printing parameters (namely, the spacing between subsequent drops deposited on the substrate, the printing speed, and the nozzle temperature) on the accuracy of a representative geometry consisting of two interdigitated comb-shape electrodes. The study objective was achieved thanks to a proper experimental campaign developed according to Design of Experiments (DoE) methodology. The printing process performance was evaluated by suitable geometrical quantities extracted from the acquired images of the printed samples using a MATLAB algorithm. A drop spacing of 140 µm and 170 µm on the two main directions of the printing plane, with a nozzle temperature of 35 °C, resulted as the most appropriate parameter combination for printing the target geometry. No significant influence of the printing speed on the process outcomes was found, thus choosing the highest speed value within the investigated range can increase productivity.

Low-cost and cleanroom-free prototyping of microfluidic and electrochemical biosensors: Techniques in fabrication and bioconjugation

Integrated microfluidic biosensors enable powerful microscale analyses in biology, physics, and chemistry. However, conventional methods for fabrication of biosensors are dependent on cleanroom-based approaches requiring facilities that are expensive and are limited in access. This is especially prohibitive toward researchers in low- and middle-income countries. In this topical review, we introduce a selection of state-of-the-art, low-cost prototyping approaches of microfluidics devices and miniature sensor electronics for the fabrication of sensor devices, with focus on electrochemical biosensors. Approaches explored include xurography, cleanroom-free soft lithography, paper analytical devices, screen-printing, inkjet printing, and direct ink writing. Also reviewed are selected surface modification strategies for bio-conjugates, as well as examples of applications of low-cost microfabrication in biosensors. We also highlight several factors for consideration when selecting microfabrication methods appropriate for a project. Finally, we share our outlook on the impact of these low-cost prototyping strategies on research and development. Our goal for this review is to provide a starting point for researchers seeking to explore microfluidics and biosensors with lower entry barriers and smaller starting investment, especially ones from low resource settings.

Fully Inkjet-Printed Biosensors Fabricated with a Highly Stable Ink Based on Carbon Nanotubes and Enzyme-Functionalized Nanoparticles

Enzyme inks can be inkjet printed to fabricate enzymatic biosensors. However, inks containing enzymes present a low shelf life because enzymes in suspension rapidly lose their catalytic activity. Other major problems of printing these inks are the non-specific adsorption of enzymes onto the chamber walls and stability loss during printing as a result of thermal and/or mechanical stress. It is well known that the catalytic activity can be preserved for significantly longer periods of time and to harsher operational conditions when enzymes are immobilized onto adequate surfaces. Therefore, in this work, horseradish peroxidase was covalently immobilized onto silica nanoparticles. Then, the nanoparticles were mixed into an aqueous ink containing single walled carbon nanotubes. Electrodes printed with this specially formulated ink were characterized, and enzyme electrodes were printed. To test the performance of the enzyme electrodes, a complete amperometric hydrogen peroxide biosensor was fabricated by inkjet printing. The electrochemical response of the printed electrodes was evaluated by cyclic voltammetry in solutions containing redox species, such as hexacyanoferrate (III/II) ions or hydroquinone. The response of the enzyme electrodes was studied for the amperometric determination of hydrogen peroxide. Three months after the ink preparation, the printed enzyme electrodes were found to still exhibit similar sensitivity, demonstrating that catalytic activity is preserved in the proposed ink. Thus, enzyme electrodes can be successfully printed employing highly stable formulation using nanoparticles as carriers.

Characterization of Inkjet-Printed Digital Microfluidics Devices

Digital microfluidics (DMF) devices enable precise manipulation of small liquid volumes in point-of-care testing. A printed circuit board (PCB) substrate is commonly utilized to build DMF devices. However, inkjet printing can be used to fabricate DMF circuits, providing a less expensive alternative to PCB-based DMF designs while enabling more rapid design iteration cycles. We demonstrate the cleanroom-free fabrication process of a low-cost inkjet-printed DMF circuit. We compare Kapton and polymethyl methacrylate (PMMA) as dielectric coatings by measuring the minimal droplet actuation voltage for a range of actuation frequencies. A minimum actuation voltage of 5.6 V was required for droplet movement with the PMMA layer thickness of 0.2 μm and a hydrophobic layer of 0.17 μm. Significant issues with PMMA dielectric breakdown were observed at actuation voltages above 10 V. In comparison, devices that utilized Kapton were found to be more robust, even at an actuation voltage up to 100 V.

Recent Advances in Printed Capacitive Sensors

In this review paper, we summarize the latest advances in the field of capacitive sensors fabricated by printing techniques. We first explain the main technologies used in printed electronics, pointing out their features and uses, and discuss their advantages and drawbacks. Then, we review the main types of capacitive sensors manufactured with different materials and techniques from physical to chemical detection, detailing the main substrates and additives utilized, as well as the measured ranges. The paper concludes with a short notice on status and perspectives in the field.

Polymeric Transducers: An Inkjet Printed B-Field Sensor with Resistive Readout Strategy

Magnetic field sensors are successfully used in numerous application contexts such as position sensing, speed detection, current detection, contactless switches, vehicle detection, and electronic compasses. In this paper, an inkjet printed magnetic sensor, based on the magneto-mechanical sensing principle, is presented together with a physical model describing its physical behavior and experimental results. The main novelties of the proposed solution consist of its low cost, rapid prototyping (printing and drying time), disposability, and in the use of a commercial low-cost printer. A measurement survey has been carried out by investigating magnetic fields belonging to the range 0–27 mT and for different values of the excitation current forced in the actuation coil. Experimental results demonstrate the suitability of both the proposed sensing strategy and model developed. In particular, in the case of an excitation current of 100 mA, the device responsivity and resolution are 3700 µε/T and 0.458 mT, respectively.

Inkjet-Printed Carbon Nanotubes for Fabricating a Spoof Fingerprint on Paper

A spoof fingerprint was fabricated on paper and applied for a spoofing attack to unlock a smartphone on which a capacitive array of sensors had been embedded with a fingerprint recognition algorithm. Using an inkjet printer with an ink made of carbon nanotubes (CNTs), we printed a spoof fingerprint having an electrical and geometric pattern of ridges and furrows comparable to that of the real fingerprint. With this printed spoof fingerprint, we were able to unlock a smartphone successfully; this was due to the good quality of the printed CNT material, which provided electrical conductivities and structural patterns similar to those of the real fingerprint. This result confirms that inkjet-printing CNTs to fabricate a spoof fingerprint on paper is an easy, simple spoofing route from the real fingerprint and suggests a new method for outputting the physical ridges and furrows on a two-dimensional plane.

Fully Solution-Processed Transparent Artificial Neural Network Using Drop-On-Demand Electrohydrodynamic Printing

Artificial neural networks (ANN), deep learning, and neuromorphic systems are exciting new processing architectures being used to implement a wide variety of intelligent and adaptive systems. To date, these architectures have been primarily realized using traditional complementary metal-oxide-semiconductor (CMOS) processes or otherwise conventional semiconductor fabrication processes. Thus, the high cost associated with the design and fabrication of these circuits has limited the broader scientific community from applying new ideas, and arguably, has slowed research progress in this exciting new area. Solution-processed electronics offer an attractive option for providing low-cost rapid prototyping of neuromorphic devices. This article proposes a novel, wholly solution-based process used to produce low-cost transparent synaptic transistors capable of emulating biological synaptic functioning and thus used to construct ANN. We have demonstrated the fabrication process by constructing an ANN that encodes and decodes a 100 × 100 pixel image. Here, the synaptic weights were configured to achieve the desired image processing functions.

Direct Printing of a Multi-Layer Sensor on Pet Substrate for CO2 Detection

The use of inexpensive gas sensors is a real need for many applications requiring the use of disposable sensors. This work deals with the realization and characterization of a low cost CO2 sensor realized by rapid prototyping techniques. In particular, the sensor consists of a set of InterDigiTed electrodes, over which a double sensing layer made of PEDOT/PSS (CLEVIOS™ PHCV4, by H.C.Starck) and a solution of pristine graphene powder has been deposited. A silver nano-particle solution is used for inkjet printing the electrodes onto the PET (PolyEthylene Terephthalate) substrate, through a commercial inkjet printer. The sensing strategy is based on the variation of the electrical conductance of graphene due to gas molecules adsorption. The device responsivity observed in two different operating conditions (50 °C and 60 °C), is 4.0 µΩ/Ω/ppm and 4.7 µΩ/Ω/ppm. The corresponding values of the resolution are 400 ppm and 420 ppm. Main advantages of the developed sensor consist in the cost-effective fabrication techniques and the device flexibility, which are strategic for applications requiring disposable and shapeable devices to be installed into irregular surfaces.

A flexible enzyme-electrode sensor with cylindrical working electrode modified with a 3D nanostructure for implantable continuous glucose monitoring

A novel cylindrical flexible enzyme-electrode sensor was fabricated with a bigger working electrode (WE) surface than the traditional pin-like one for implantable continuous glucose monitoring. On the WE surface, a 3D nanostructure consisting of graphene and platinum nanoparticles was constructed to enhance the sensitivity; in conjunction with the bigger WE, this nanostructure enabled hypoglycemia detection, which is still a big challenge in clinics. The cylindrical sensor was fabricated by rotated inkjet printing which enabled direct patterning of microstructures on a curved surface, thus overcoming the restriction of the traditional planar micromachining by photolithography. Specifically, the cylindrical substrate (polyetheretherketone, PEEK) was modified by (3-aminopropyl) trimethoxysilane and (3-mercaptopropyl) trimethoxysilane to facilitate surface wettability, which discourages the coalescence of adjacent droplets, and to facilitate the adhesion of metals to PEEK in order to construct robust electrodes. A synchronous heating method was used to evaporate the solvent of the droplets quickly to prevent them from running along the cylindrical surface, which affects the formation of the printed electrode significantly. In vitro experimental results showed that the proposed sensor was able to detect the glucose concentration ranging from 0 to 570 mg dL^-1 which demonstrated its capability for physiological glucose detection. In vivo experiments were conducted with rats, and the measurement results recorded using the implanted cylindrical sensor showed great compliance to those recorded using a commercial glucometer which exhibited the viability of the proposed sensor for implantable continuous glucose monitoring, even under the hypoglycemic conditions.

Review of Recent Inkjet-Printed Capacitive Tactile Sensors

Inkjet printing is an advanced printing technology that has been used to develop conducting layers, interconnects and other features on a variety of substrates. It is an additive manufacturing process that offers cost-effective, lightweight designs and simplifies the fabrication process with little effort. There is hardly sufficient research on tactile sensors and inkjet printing. Advancements in materials science and inkjet printing greatly facilitate the realization of sophisticated tactile sensors. Starting from the concept of capacitive sensing, a brief comparison of printing techniques, the essential requirements of inkjet-printing and the attractive features of state-of-the art inkjet-printed tactile sensors developed on diverse substrates (paper, polymer, glass and textile) are presented in this comprehensive review. Recent trends in inkjet-printed wearable/flexible and foldable tactile sensors are evaluated, paving the way for future research.