Sacrificial methods using polystyrene (PS) templates are extensively applied in various research fields, particularly for fabricating gas sensors. The many processing advantages of these methods, such as a uniform particle size distribution, ease of manipulation, and potential for functionalization enable the fabrication of intricate nanostructures with precise control of the geometry and surface-area-to-volume ratio. Nevertheless, no previous study has investigated the fundamental correlation between the size of the PS particles used as a template and the performance of the resulting functional gas sensor. In this study, we fabricated In2O3 hollow hemispheres (HHs) with PS template sizes ranging from 200 to 3000 nm to explore the essential aspects for gas sensor applications. Notably, compared to In2O3 thin films, In2O3 HHs-based sensors prepared using a 3000 nm PS template exhibited a larger surface area, particularly when formed in a monolayer, and achieved an enhanced gas response to C2H5OH by approximately 132 times. By decorating In2O3 HHs with Au nanoparticles, the detection of C5H8 at 350 ℃ among various volatile organic compounds was significantly enhanced (increase ratio = 31.7), achieving a response of 483 and a theoretical detection limit as low as 743 parts per trillion (ppt). In addition, the highly porous structure with Au decoration achieved an extremely short response time of less than 2 s. These unprecedented results provide critical insights into conventional sensor technologies and pave the way for potential health-monitoring applications and bioelectronics.
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