Aerosol‐Jet Printed Sensors for Environmental, Safety, and Health Monitoring: A Review

Abstract

An emergent direct‐write approach, aerosol‐jet printing (AJP), is gaining attention for the deployment of rapid and affordable microadditively manufactured energy‐efficient sensors and printed electronics. AJP enables a broad range of ink viscosities (0.001–1 Pa s) for printing diverse materials ranging from ceramics and metals to polymers and biological matter. Reproducible, high‐spatial‐resolution features (≈10 µm), and wide standoff distances (1–11 mm) between the nozzle and the substrate facilitate conformal printing of complex geometrical designs on nonplanar—e.g., stepped or curved—surfaces. This paper aims to provide a comprehensive overview of state‐of‐the‐art AJP‐based sensors (e.g., strain and temperature gauges, biosensors, photosensors, humidity and surface acoustic wave sensors, dielectric elastomer actuators, and motion, smoke, and hazardous gas detectors) and to discuss prospective applications. The drive toward cost‐effective devices that are smaller, lighter, and better‐performing remains a frontier challenge in the field of printed electronics. Consequently, as AJP becomes increasingly utilized in the high‐volume manufacturing of miniaturized active and passive sensors, it opens a pathway for facile large‐scale fabrication of devices for a wide range of consumer and industrial applications, including transportation, agriculture, infrastructure, aerospace, national defense, and healthcare.

Facile Fabrication of “Tacky”, Stretchable, and Aligned Carbon Nanotube Sheet-Based Electronics for On-Skin Health Monitoring

“…In comparison to the state-of-the-art digital printing technologies such as inkjet printing, aerosol jet printing, or direct ink writing, our simple stamping method using aligned CNT sheets for health monitoring is in an early stage of development. Then, work is still needed to identify the limitations of the method to improve and expand its capabilities.…”

Aerosol Jet Printing-Enabled Dual-Function Electrochemical and Colorimetric Biosensor for SARS-CoV-2 Detection

“…Furthermore, aerosol inkjet printing is a highly versatile and precise printing technique that offers unique advantages in terms of material compatibility, resolution, and flexibility . Its applications range from printed electronics and sensors to biotechnology and beyond, making it a promising technology for numerous industries seeking innovative and efficient printing solutions …”

“…44 Its applications range from printed electronics and sensors to biotechnology and beyond, making it a promising technology for numerous industries seeking innovative and efficient printing solutions. 45 ■ ASSOCIATED CONTENT * sı Supporting Information…”

Integrated pH Sensors Based on RuO2/GO Nanocomposites Fabricated Using the Aerosol Jet Printing Method

“…Printing techniques are a widely explored method for the precise patterning of advanced nanomaterials and are used in various applications, including flexible displays, electronics packaging, and health-related sensors. − Among the established printing methods, aerosol jet printing (AJP), a 2D printing method, is a relatively recent addition to the printing toolbox. Its noncontact nature allows for precise, high-resolution structures, reaching as fine as 10 μm. , The noncontact feature minimizes contamination and material damage, ensuring sensor integrity. AJP’s high-resolution capability enables precise deposition of functional materials, allowing for complex sensor architectures.…”

“…Its noncontact nature allows for precise, highresolution structures, reaching as fine as 10 μm. 4,5 The noncontact feature minimizes contamination and material damage, ensuring sensor integrity. AJP's high-resolution capability enables precise deposition of functional materials, allowing for complex sensor architectures.…”