Recent Progress in Conducting Polymer Composite/Nanofiber-Based Strain and Pressure Sensors

The Conducting of polymers belongs to the class of polymers exhibiting excellence in electrical performances because of their intrinsic delocalized π- electrons and their tunability ranges from semi-conductive to metallic conductive regime. Conducting polymers and their composites serve greater functionality in the application of strain and pressure sensors, especially in yielding a better figure of merits, such as improved sensitivity, sensing range, durability, and mechanical robustness. The electrospinning process allows the formation of micro to nano-dimensional fibers with solution-processing attributes and offers an exciting aspect ratio by forming ultra-long fibrous structures. This review comprehensively covers the fundamentals of conducting polymers, sensor fabrication, working modes, and recent trends in achieving the sensitivity, wide-sensing range, reduced hysteresis, and durability of thin film, porous, and nanofibrous sensors. Furthermore, nanofiber and textile-based sensory device importance and its growth towards futuristic wearable electronics in a technological era was systematically reviewed to overcome the existing challenges.

Combination of Ceramic Laser Micromachining and Printed Technology as a Way for Rapid Prototyping Semiconductor Gas Sensors

The work describes a fast and flexible micro/nano fabrication and manufacturing method for ceramic Micro-electromechanical systems (MEMS)sensors. Rapid prototyping techniques are demonstrated for metal oxide sensor fabrication in the form of a complete MEMS device, which could be used as a compact miniaturized surface mount devices package. Ceramic MEMS were fabricated by the laser micromilling of already pre-sintered monolithic materials. It has been demonstrated that it is possible to deposit metallization and sensor films by thick-film and thin-film methods on the manufactured ceramic product. The results of functional tests of such manufactured sensors are presented, demonstrating their full suitability for gas sensing application and indicating that the obtained parameters are at a level comparable to those of industrial produced sensors. Results of design and optimization principles of applied methods for micro- and nanosystems are discussed with regard to future, wider application in semiconductor gas sensors prototyping.

Manufacturing Process of Polymeric Microneedle Sensors for Mass Production

In this work, we present a fabrication process for microneedle sensors made of polylactic acid (PLA), which can be utilized for the electrochemical detection of various biomarkers in interstitial fluid. Microneedles were fabricated by the thermal compression molding of PLA into a laser machined polytetrafluoroethylene (PTFE) mold. Sensor fabrication was completed by forming working, counter, and reference electrodes on each sensor surface by Au sputtering through a stencil mask, followed by laser dicing to separate individual sensors from the substrate. The devised series of processes was designed to be suitable for mass production, where multiple microneedle sensors can be produced at once on a 4-inch wafer. The operational stability of the fabricated sensors was confirmed by linear sweep voltammetry and cyclic voltammetry at the range of working potentials of various biochemical molecules in interstitial fluid.

Selective and self-validating breath-level detection of hydrogen sulfide in humid air by gold nanoparticle-functionalized nanotube arrays

We demonstrate the selective detection of hydrogen sulfide at breath concentration levels under humid airflow, using a self-validating 64-channel sensor array based on semiconducting single-walled carbon nanotubes (sc-SWCNTs). The reproducible sensor fabrication process is based on a multiplexed and controlled dielectrophoretic deposition of sc-SWCNTs. The sensing area is functionalized with gold nanoparticles to address the detection at room temperature by exploiting the affinity between gold and sulfur atoms of the gas. Sensing devices functionalized with an optimized distribution of nanoparticles show a sensitivity of 0.122%/part per billion (ppb) and a calculated limit of detection (LOD) of 3 ppb. Beyond the self-validation, our sensors show increased stability and higher response levels compared to some commercially available electrochemical sensors. The cross-sensitivity to breath gases NH3 and NO is addressed demonstrating the high selectivity to H2S. Finally, mathematical models of sensors’ electrical characteristics and sensing responses are developed to enhance the differentiation capabilities of the platform to be used in breath analysis applications.

CHLORIDE SENSOR FABRICATION BASED ON SPE Ag/AgCl THROUGH CYCLIC VOLTAMMETRIC TECHNIQUE: SCAN RATE EFFECT

The Cyclic Voltammetric (CV) technique is one of the Ag/AgCl fabrication processes. In electrochemical processes using this CV technique, the microstructure of the surface of a substrate or electrode can affect the scan rate. Thus, this study aims to identify the scan rate effect of the Cl-ion sensor fabrication process using the CV technique on the performance of the Cl-ion sensor. First, the CV process was carried out in one cycle to grow the AgCl layer on the Ag surface. Then, this process was carried out at varied scan rates of 20, 40, 60, 80, and 100 mV/s. After completing the Ag/AgCl fabrication process, it was followed by the characterization process, selectivity coefficient test, lifetime test, and validation test to compare the test results of the Cl SPE Ag/AgCl ion sensor with Ag/AgCl commercial. The results showed that the optimum Cl-ion sensor response was obtained at the scan rate of 60 mV/s. Then, based on the validation test, the Cl-ion in the two samples did not show significant differences. Therefore, it indicates that the SPE Ag/AgCl ion sensor has the same performance as the Ag/AgCl commercial.

An Inkjet-Printed Amperometric H2S Sensor for Environmental Applications

Hydrogen sulfide (H2S) is a highly toxic chemical capable of causing severe health issues. Due to its environmental impact, it is critical to create effective methods for its monitoring. Inkjet printing technology has become an alternative for sensor fabrication because it is an economic, fast, and reproducible method for mass producing micro-electrodes. Herein, a miniaturized 25 mm2 inkjet-printed amperometric sensor is presented. A gold electrode coupled with a silver track was modified with two inks: single-walled carbon nanotubes (SWCNTs) and a mixture of SCWCNTs and poly(vinyl alcohol) (PVA). Morphological and electrochemical properties were studied, as well as H2S sensor performance. This approach is a suitable option for environmental H2S tracking.

Smart Inlays for Simultaneous Crack Sensing and Arrest in Multifunctional Bondlines of Composites

Disbond arrest features combined with a structural health monitoring system for permanent bondline surveillance have the potential to significantly increase the safety of adhesive bonds in composite structures. A core requirement is that the integration of such features is achieved without causing weakening of the bondline. We present the design of a smart inlay equipped with a micro strain sensor-system fabricated on a polyvinyliden fluorid (PVDF) foil material. This material has proven disbond arrest functionality, but has not before been used as a substrate in lithographic micro sensor fabrication. Only with special pretreatment can it meet the requirements of thin film sensor elements regarding surface roughness and adhesion. Moreover, the sensor integration into composite material using a standard manufacturing procedure reveals that the smart inlays endure this process even though subjected to high temperatures, curing reactions and plasma treatment. Most critical is the substrate melting during curing when sensory function is preserved with a covering caul plate that stabilizes the fragile measuring grids. The smart inlays are tested by static mechanical loading, showing that they can be stretched far beyond critical elongations of composites before failure. The health monitoring function is verified by testing the specimens with integrated sensors in a cantilever bending setup. The results prove the feasibility of micro sensors detecting strain gradients on a disbond arresting substrate to form a so-called multifunctional bondline.