Printing technologies have been attracting increasing interest in the manufacture of electronic devices and sensors. They offer a unique set of advantages such as additive material deposition and low to no material waste, digitally-controlled design and printing, elimination of multiple steps for device manufacturing, wide material compatibility and large scale production to name but a few. Some of the most popular and interesting sensors are relative humidity, temperature and strain sensors. In that regard, this review analyzes the utilization and involvement of printing technologies for full or partial sensor manufacturing; production methods, material selection, sensing mechanisms and performance comparison are presented for each category, while grouping of sensor sub-categories is performed in all applicable cases. A key aim of this review is to provide a reference for sensor designers regarding all the aforementioned parameters, by highlighting strengths and weaknesses for different approaches in printed humidity, temperature and strain sensor manufacturing with printing technologies.

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The present work reports on the detailed electro-thermal evaluation of a highly water dispersible, functionalized reduced graphene oxide (f-rGO) using inkjet printing technology. Aiming in the development of printed electronic devices, a flexible polyimide substrate was used for the structures’ formation. A direct comparison between the f-rGO ink dispersion and a commercial graphene inkjet ink is also presented. Extensive droplet formation analysis was performed in order to evaluate the repeatable and reliable jetting from an inkjet printer under study. Electrical characterization was conducted and the electrical characteristics were assessed under different temperatures, showing that the water dispersion of the f-rGO is an excellent candidate for application in printed thermal sensors and microheaters. It was observed that the proposed f-rGO ink presents a tenfold increased temperature coefficient of resistance compared to the commercial graphene ink (G). A successful direct interconnection implementation of both materials with commercial Ag-nanoparticle ink lines was also demonstrated, thus allowing the efficient electrical interfacing of the printed structures. The investigated ink can be complementary utilized for developing fully printed devices with various characteristics, all on flexible substrates with cost-effective, few-step processes.

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Thermal sensors are mainly based on the selective heating of specific areas, which in most cases is a critical feature for both the operation and the performance of the thermal device. In this work, we evaluate the thermoelectrical response of two graphitic materials, namely (a) a commercial 2.4%wt graphene–ethyl cellulose dispersion in cycloxehanone and terpineol (G) and (b) a custom functionalized reduced graphene oxide (f-rGO) ink in the range of −40 to 100 °C. Both inks were printed on a flexible polyimide substrate and the Thermal Coefficients of Resistance (TCR) were extracted as TCRG = −1.05 × 10−3 °C−1 (R2 = 0.9938) and TCRf-rGO = −3.86 × 10−3 °C−1 (R2 = 0.9967). Afterward, the inkjet-printed devices were evaluated as microheaters, in order to exploit their advantage for cost-effective production with minimal material waste. f-rGO and G printed heaters reached a maximum temperature of 97.5 °C at 242 mW and 89.9 °C at 314 mW, respectively, applied by a constant current source and monitored by an infrared camera. Repeatability experiments were conducted, highlighting the high robustness in long-term use. The power–temperature behavior was extracted by self-heating experiments to demonstrate the ability of the devices to serve as heaters. Both static and dynamic evaluation were performed in order to study the device behaviors and extract the corresponding parameters. After all the experimental processes, the resistance of the samples was again evaluated and found to differ less than 13% from the initial value. In this work, fabrication via inkjet printing and demonstration of efficient and stable microheaters utilizing a custom ink (f-rGO) and a commercial graphene ink are presented. This approach is suitable for fabricating selectively heated geometries on non-planar substrate with high repeatability and endurance in heat cycles.

The development and the corresponding evaluation of a multidirectional thermal flow sensor are presented in this work. The sensor was fabricated on a flexible substrate, allowing for new applications, since it provides the possibility of installation in nonplanar surfaces such as pipelines. Furthermore, the sensing elements are not in direct contact with the fluid, which increases the device reliability, extends its application range, and allows the noncontact monitoring of fluids. This was achieved by utilizing the substrate as a protective layer between the sensing elements and the fluid under measurement. The operation principle is based on the determination of the flow-induced temperature profile variations. A dedicated experimental setup was designed and used for the device evaluation. Both flow velocity value and direction were successfully extracted, while the results were consistent with the predicted theoretical values. A single-layer back propagation neural network that correlates the sensors’ readouts to the angle of rotation was implemented, which leads to a mean absolute direction estimation error in the order of 2.7 degrees independent to the training procedure datasets.

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In this work we present the development of a low-cost humidity and temperature sensing platform on paper by inkjet printing, using a commercial AgNPs conductive ink. The humidity sensing module was capable of measuring relative humidity in the range of 0-90%rH, exhibiting linear response with minimal memory effect when returning to 0%rH baseline signal while the temperature sensor performed linearly as well in the range of 25-75°C. Process repeatability has been verified by electrical and optical characterization. Mechanical bending results highlight the platform's capability to serve as an easy to install, flexible multi-parametric sensing platform.