The Additive to Mass Manufacturing Process of Mixed Potential Electrochemical Sensors

Abstract

Additive manufacturing allows for quick turn around and low cost of production of small numbers of parts. These attributes lend the technology to prototype development, where design changes are many and production numbers are low [1]. Once design parameters have been nailed down, additive manufacturing’s low throughput and poor reproducibility limit application to high volume production.Here, we discuss the implementation of direct-write extrusion of ceramic pastes and metal inks for prototype manufacturing of mixed potential electrochemical sensors and the transition to tape casting and screen printing for high volume production. Throughout the prototyping phase, direct write extrusion enabled quick and easy production of low numbers of parts, enabling various changes in sensor design and material to improve sensor performance. Sensor design evolved from a disk shape (Fig. 1 a) to a stick with integrated heater (Fig. 1 b, c). Direct write extrusion of substrate enabled quick testing of various stabilized zirconia ceramics to improve the sensitivity of the device [2]. Limitations of additive manufacturing became apparent when attempting to integrate the heater into the device, the inconsistent linewidths led to areas of high resistance and hot spots (Fig. 1 c). Tape-casting and screen printing of the devices was adopted for three reasons, first, to improve line fidelity, which is vitally important when printing small electrodes as well as heater traces (Fig. 1 d), second, to further decrease conductivity of substrate by laminating multiple layers of different ceramic materials, and finally to increase manufacturing throughput (Fig. 1 d, e).This work was supported by US Department of Energy Award DE-FE0031864References[1] T. D. Ngo, A. Kashani, G. Imbalzano, K. T. Q. Nguyen, and D. Hui, “Additive manufacturing (3D printing): A review of materials, methods, applications and challenges,” Compos. Part B Eng., vol. 143, pp. 172–196, Jun. 2018, doi: 10.1016/j.compositesb.2018.02.012.[2] S. Halley, K. Ramaiyan, F. Garzon, and L. Tsui, “Massive enhancement in sensitivity of mixed potential sensors towards methane and natural gas through magnesia stabilized zirconia low ionic conductivity substrate,” Sens. Actuators B Chem., vol. 392, p. 134031, Oct. 2023, doi: 10.1016/j.snb.2023.134031. Figure 1