During
the γ-radiation sterilization process, the levels
of radiation exposure to a medical device must be carefully monitored
to achieve the required sterilization without causing deleterious
effects on its intended physical and chemical properties. To address
this issue, here we have demonstrated the development of an all-printed
disposable low-cost sensor that exploits the change in electrical
impedance of a semi-interpenetrating polymer network (SIPN) composed
of poly(vinyl alcohol) (PVA) and poly(3,4-ethylenedioxythiophene):polystyrenesulfonate
(PEDOT:PSS) as a functional polymer composite for radiation sterilization
monitoring applications. Specifically, the PEDOT:PSS acts as the electrically
conductive medium, while the PVA provides the ductility and stability
of the printed sensors. During irradiation exposure, chain scission
and cross-linking events occur concurrently in the PEDOT:PSS and PVA
polymer chains, respectively. The concurrent scissoring of the PEDOT
polymer and cross-linking of the PVA polymer network leads to the
formation of a stable SIPN with reduced electrical conductivity, which
was verified through FTIR, Raman, and TGA analysis. Systematic studies
of different ratios of PEDOT:PSS and PVA mixtures were tested to identify
the optimal ratio that provided the highest radiation sensitivity
and stability performance. The results showed that PEDOT:PSS/PVA composites
with 10 wt % PVA produced sensors with relative impedance changes
of 30% after 25 kGy and up to 370% after 53 kGy (which are two of
the most commonly used radiation exposure levels for sterilization
applications). This composition showed high electrical impedance stability
with less than ±5% change over 18 days after irradiation exposure.
These findings demonstrate the feasibility of utilizing a printing
technology for scalable manufacturing of low-cost, flexible radiation
sensors for more effective monitoring of radiation sterilization processes.