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Gamba L, Razzaq MEA, Diaz-Arauzo S, Hersam MC, Bai X, Secor EB. Tailoring Electrical Properties in Carbon Nanomaterial Patterns with Multimaterial Aerosol Jet Printing. ACS Appl Mater Interfaces 2023. [PMID: 38048513 DOI: 10.1021/acsami.3c15088] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/06/2023]
Abstract
Multimaterial aerosol jet printing offers a unique capability to freely mix inks with different chemical compositions in the aerosol phase, enabling one-step digital fabrication with tailored compositions or functionally graded structures, including in the x-y plane. Here, in situ mixing of two carbon nanomaterial inks with distinct electrical properties is demonstrated. By tailoring the mixing ratio of the constituent inks, electrical conductivity is modulated by 130×, and sheet resistance values for a single pass span approximately 2 orders of magnitude. The ability to manufacture components with tailored electrical properties offers significant value for hybrid and flexible electronic device applications, such as microelectronics packaging. Moreover, grading properties within a part provides a new dimension of design freedom for complex assemblies.
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Affiliation(s)
- Livio Gamba
- Department of Mechanical Engineering, Iowa State University, Ames, Iowa 50010, United States
| | - Moham Ed Abdur Razzaq
- Department of Mechanical Engineering, Iowa State University, Ames, Iowa 50010, United States
| | - Santiago Diaz-Arauzo
- Department of Materials Science and Engineering, Northwestern University, Evanston, Illinois 60208, United States
| | - Mark C Hersam
- Department of Materials Science and Engineering, Northwestern University, Evanston, Illinois 60208, United States
- Department of Chemistry, Northwestern University, Evanston, Illinois 60208, United States
- Department of Electrical and Computer Engineering, Northwestern University, Evanston, Illinois 60208, United States
| | - Xianglan Bai
- Department of Mechanical Engineering, Iowa State University, Ames, Iowa 50010, United States
| | - Ethan B Secor
- Department of Mechanical Engineering, Iowa State University, Ames, Iowa 50010, United States
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Downing JR, Diaz-Arauzo S, Chaney LE, Tsai D, Hui J, Seo JWT, Cohen DR, Dango M, Zhang J, Williams NX, Qian JH, Dunn JB, Hersam MC. Centrifuge-Free Separation of Solution-Exfoliated 2D Nanosheets via Cross-Flow Filtration. Adv Mater 2023; 35:e2212042. [PMID: 36934307 DOI: 10.1002/adma.202212042] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/22/2022] [Revised: 02/26/2023] [Indexed: 06/16/2023]
Abstract
Solution-processed graphene is a promising material for numerous high-volume applications including structural composites, batteries, sensors, and printed electronics. However, the polydisperse nature of graphene dispersions following liquid-phase exfoliation poses major manufacturing challenges, as incompletely exfoliated graphite flakes must be removed to achieve optimal properties and downstream performance. Incumbent separation schemes rely on centrifugation, which is highly energy-intensive and limits scalable manufacturing. Here, cross-flow filtration (CFF) is introduced as a centrifuge-free processing method that improves the throughput of graphene separation by two orders of magnitude. By tuning membrane pore sizes between microfiltration and ultrafiltration length scales, CFF can also be used for efficient recovery of solvents and stabilizing polymers. In this manner, life cycle assessment and techno-economic analysis reveal that CFF reduces greenhouse gas emissions, fossil energy usage, water consumption, and specific production costs of graphene manufacturing by 57%, 56%, 63%, and 72%, respectively. To confirm that CFF produces electronic-grade graphene, CFF-processed graphene nanosheets are formulated into printable inks, leading to state-of-the-art thin-film conductivities exceeding 104 S m-1 . This CFF methodology can likely be generalized to other van der Waals layered solids, thus enabling sustainable manufacturing of the diverse set of applications currently being pursued for 2D materials.
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Affiliation(s)
- Julia R Downing
- Department of Materials Science and Engineering, Northwestern University, 2220 Campus Dr., Evanston, IL, 60208, USA
| | - Santiago Diaz-Arauzo
- Department of Materials Science and Engineering, Northwestern University, 2220 Campus Dr., Evanston, IL, 60208, USA
| | - Lindsay E Chaney
- Department of Materials Science and Engineering, Northwestern University, 2220 Campus Dr., Evanston, IL, 60208, USA
| | - Daphne Tsai
- Department of Materials Science and Engineering, Northwestern University, 2220 Campus Dr., Evanston, IL, 60208, USA
| | - Janan Hui
- Department of Chemistry, Northwestern University, 2145 Sheridan Rd., Evanston, IL, 60208, USA
| | - Jung-Woo T Seo
- Department of Materials Science and Engineering, Northwestern University, 2220 Campus Dr., Evanston, IL, 60208, USA
| | | | - Michael Dango
- Cytiva, 100 Results Way, Marlborough, MA, 01752, USA
| | - Jinrui Zhang
- Department of Chemical and Biological Engineering, Northwestern University, 2145 Sheridan Rd., Evanston, IL, 60208, USA
| | - Nicholas X Williams
- Department of Materials Science and Engineering, Northwestern University, 2220 Campus Dr., Evanston, IL, 60208, USA
| | - Justin H Qian
- Department of Materials Science and Engineering, Northwestern University, 2220 Campus Dr., Evanston, IL, 60208, USA
| | - Jennifer B Dunn
- Department of Chemical and Biological Engineering, Northwestern University, 2145 Sheridan Rd., Evanston, IL, 60208, USA
| | - Mark C Hersam
- Department of Materials Science and Engineering, Northwestern University, 2220 Campus Dr., Evanston, IL, 60208, USA
- Department of Chemistry, Northwestern University, 2145 Sheridan Rd., Evanston, IL, 60208, USA
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Gamba L, Johnson ZT, Atterberg J, Diaz-Arauzo S, Downing JR, Claussen JC, Hersam MC, Secor EB. Systematic Design of a Graphene Ink Formulation for Aerosol Jet Printing. ACS Appl Mater Interfaces 2023; 15:3325-3335. [PMID: 36608034 DOI: 10.1021/acsami.2c18838] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/17/2023]
Abstract
Aerosol jet printing is a noncontact, digital, additive manufacturing technique compatible with a wide variety of functional materials. Although promising, development of new materials and devices using this technique remains hindered by limited rational ink formulation, with most recent studies focused on device demonstration rather than foundational process science. In the present work, a systematic approach to formulating a polymer-stabilized graphene ink is reported, which considers the effect of solvent composition on dispersion, rheology, wetting, drying, and phase separation characteristics that drive process outcomes. It was found that a four-component solvent mixture composed of isobutyl acetate, diglyme, dihydrolevoglucosenone, and glycerol supported efficient ink atomization and controlled in-line drying to reduce overspray and wetting instabilities while maintaining high resolution and electrical conductivity, thus overcoming a trade-off in deposition rate and resolution common to aerosol jet printing. Biochemical sensors were printed for amperometric detection of the pesticide parathion, exhibiting a detection limit of 732 nM and a sensitivity of 34 nA μM-1, demonstrating the viability of this graphene ink for fabricating functional electronic devices.
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Affiliation(s)
- Livio Gamba
- Department of Mechanical Engineering, Iowa State University, Ames, Iowa 50010, United States
| | - Zachary T Johnson
- Department of Mechanical Engineering, Iowa State University, Ames, Iowa 50010, United States
| | - Jackie Atterberg
- Department of Mechanical Engineering, Iowa State University, Ames, Iowa 50010, United States
| | - Santiago Diaz-Arauzo
- Department of Materials Science and Engineering, Northwestern University, Evanston, Illinois 60208, United States
| | - Julia R Downing
- Department of Materials Science and Engineering, Northwestern University, Evanston, Illinois 60208, United States
| | - Jonathan C Claussen
- Department of Mechanical Engineering, Iowa State University, Ames, Iowa 50010, United States
| | - Mark C Hersam
- Department of Materials Science and Engineering, Northwestern University, Evanston, Illinois 60208, United States
- Department of Chemistry, Northwestern University, Evanston, Illinois 60208, United States
- Department of Electrical and Computer Engineering, Northwestern University, Evanston, Illinois 60208, United States
| | - Ethan B Secor
- Department of Mechanical Engineering, Iowa State University, Ames, Iowa 50010, United States
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