Abstract The present study uses the co-precipitation method to explore the synthesis of zinc oxide and cobalt-doped ZnO sensors, encompassing a range of cobalt concentrations from 1 to 4 wt.%. The synthesized samples undergo comprehensive analysis to evaluate their structural, morphological, optical, and gas-sensing properties. X-ray diffraction revealed a hexagonal Wurtzite structure, and the crystallite size decreased from 16.92 to 15.39 nm. Energy-dispersive X-ray spectroscopy and Fourier-transform infrared spectroscopy collectively affirmed the presence of cobalt. Scanning electron microscopy was used to analyze the morphological characteristics. The Tauc-plot was used to determine the optical bandgap via diffuse reflectance spectroscopy. As cobalt doping increased, the band gap increased from 3.18 to 3.23 eV. Further, atomic force microscopy and Brunauer-Emmett-Teller analysis were used to assess the surface topography and pore size distribution. The AFM measurements indicated roughness within 435-700 nm. The BET analysis revealed mesoporous properties, with surface area ranging between 18.657 to 21.962 m2/g. Subsequently, the gas-sensing capabilities of the Co-doped ZnO sensors were examined for various volatile organic compounds at room temperature. The sensor with 4% Cobalt doping exhibited a fast response and recovery time of 21 and 20 seconds for 2 ppm of NH3