{"id":160,"date":"2015-06-29T14:16:35","date_gmt":"2015-06-29T12:16:35","guid":{"rendered":"http:\/\/mauro-serpelloni.unibs.it\/?page_id=160"},"modified":"2026-08-26T10:54:08","modified_gmt":"2026-08-26T08:54:08","slug":"aerosol-jet-printing-and-additive-manufacturing-of-sensors","status":"publish","type":"page","link":"https:\/\/mauro-serpelloni.unibs.it\/index.php\/research-areas\/aerosol-jet-printing-and-additive-manufacturing-of-sensors\/","title":{"rendered":"Aerosol Jet Printing and Additive Manufacturing of Sensors"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\"><strong>Aerosol Jet Printing (AJP)<\/strong> is an additive manufacturing technology capable of depositing functional materials with micrometric resolution on planar, flexible and three-dimensional substrates.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Our research focuses on the use of <strong>Aerosol Jet Printing and other direct-write additive manufacturing technologies for the fabrication of sensors and electronic devices<\/strong>, with particular attention to process optimization, functional materials, unconventional substrates, curing techniques and metrological characterization.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The activity combines <strong>sensor design, printing technology, electronic measurement and materials characterization<\/strong> to investigate how manufacturing parameters affect the electrical, geometrical and sensing properties of printed devices.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Aerosol Jet Printing of Sensors<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Aerosol Jet Printing enables the direct fabrication of conductive and functional structures without conventional masks, photolithography or subtractive manufacturing processes.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The technology is particularly attractive for sensors because functional materials can be deposited directly onto the final component, including surfaces that cannot easily be processed using conventional microfabrication technologies.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Our research activities include:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Aerosol Jet Printing of sensors<\/li>\n\n\n\n<li>direct-write fabrication of electronic devices<\/li>\n\n\n\n<li>printed resistive sensors<\/li>\n\n\n\n<li>printed strain gauges<\/li>\n\n\n\n<li>printed temperature sensors<\/li>\n\n\n\n<li>printed electrodes and microelectrodes<\/li>\n\n\n\n<li>printing on flexible substrates<\/li>\n\n\n\n<li>printing on three-dimensional surfaces<\/li>\n\n\n\n<li>integration of sensors directly onto functional components<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Printing on Flexible, 3D and Temperature-Sensitive Substrates<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">One of the main advantages of additive manufacturing is the possibility of integrating sensors directly onto <strong>unconventional substrates and three-dimensional objects<\/strong>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Our research has investigated the fabrication of printed sensors on polymeric surfaces, cellulose-based materials, flexible substrates and low-melting-point plastics.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Special attention is devoted to the interaction between the printing process and the substrate, including surface morphology, adhesion, thermal limitations and geometrical effects.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This approach enables the development of <strong>embedded and conformal sensors<\/strong> for applications including biomedical devices, smart orthoses, aerospace components, smart packaging and industrial systems.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Functional Inks and Nanomaterials<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The electrical and sensing performance of printed devices strongly depends on the properties of the deposited materials.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Our research investigates conventional conductive inks as well as emerging functional nanomaterials, including:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>silver nanoparticle inks<\/li>\n\n\n\n<li>conductive nanomaterials<\/li>\n\n\n\n<li>MXene-based inks<\/li>\n\n\n\n<li>functionalized inks for chemical and electrochemical sensing<\/li>\n\n\n\n<li>nanostructured sensing layers<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">Particular attention is devoted to the relationship between ink properties, printing parameters, deposited geometry and resulting electrical characteristics.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Curing and Post-Processing<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Printed conductive structures generally require a post-processing step to obtain the required electrical and mechanical properties.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Our research investigates both conventional thermal treatments and <strong>photonic curing<\/strong>, particularly for substrates that cannot withstand high temperatures.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The effects of curing conditions are studied through measurements of:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>electrical resistance<\/li>\n\n\n\n<li>resistivity<\/li>\n\n\n\n<li>Temperature Coefficient of Resistance (TCR)<\/li>\n\n\n\n<li>geometrical stability<\/li>\n\n\n\n<li>repeatability<\/li>\n\n\n\n<li>substrate degradation<\/li>\n\n\n\n<li>sensor performance<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">These studies are particularly important when printed conductive structures are used directly as sensing elements.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Geometrical and Metrological Characterization<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Printed sensors introduce specific measurement challenges because their performance depends not only on the sensing material but also on the manufacturing process.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">For this reason, a significant part of our research is devoted to the <strong>metrological characterization of printed structures and additive manufacturing processes<\/strong>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Investigated parameters include:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>printed line width and thickness<\/li>\n\n\n\n<li>geometrical accuracy<\/li>\n\n\n\n<li>electrical resistance and resistivity<\/li>\n\n\n\n<li>printing repeatability<\/li>\n\n\n\n<li>manufacturing tolerances<\/li>\n\n\n\n<li>temperature dependence<\/li>\n\n\n\n<li>substrate effects<\/li>\n\n\n\n<li>coating effects<\/li>\n\n\n\n<li>uncertainty sources<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">The objective is to establish reliable relationships between <strong>printing parameters, geometry, material properties and sensor performance<\/strong>.<\/p>\n\n\n\n<h1 class=\"wp-block-heading\">Selected Publications<\/h1>\n\n\n\n<h2 class=\"wp-block-heading\">Journal Articles<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Printed-Strain-Gauge-on-3D-and-Low-Melting-Point-Plastic-Surface-by-Aerosol-Jet-Printing-and-Photonic-Curing.pdf\">Printed Strain Gauge on 3D and Low-Melting Point Plastic Surface by Aerosol Jet Printing and Photonic Curing<\/a><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">M. Borghetti, M. Serpelloni, E. Sardini<br><em>Sensors<\/em>, 19, 4220, 2019.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This work demonstrates the direct fabrication of a strain gauge on a three-dimensional, low-melting-point polymer surface using Aerosol Jet Printing combined with photonic curing.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>DOI:<\/strong> <a href=\"https:\/\/doi.org\/10.3390\/s19194220\">10.3390\/s19194220<\/a> | <strong><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Printed-Strain-Gauge-on-3D-and-Low-Melting-Point-Plastic-Surface-by-Aerosol-Jet-Printing-and-Photonic-Curing.pdf\">Download PDF<\/a><\/strong><\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Printed-Smart-Devices-on-Cellulose-Based-Materials-by-means-of-Aerosol-Jet-Printing-and-Photonic-Curing.pdf\">Printed Smart Devices on Cellulose-Based Materials by Means of Aerosol-Jet Printing and Photonic Curing<\/a><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">M. Serpelloni, E. Cant\u00f9, M. Borghetti, E. Sardini<br><em>Sensors<\/em>, 20, 841, 2020.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The study investigates the fabrication of printed electronic devices on different cellulose-based substrates and the use of photonic curing for processing temperature-sensitive materials.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>DOI:<\/strong> <a href=\"https:\/\/doi.org\/10.3390\/s20030841\">10.3390\/s20030841<\/a> | <strong><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Printed-Smart-Devices-on-Cellulose-Based-Materials-by-means-of-Aerosol-Jet-Printing-and-Photonic-Curing.pdf\">Download PDF<\/a><\/strong><\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Temperature-influence-on-Ti3C2Tx-lines-printed-by-aerosol-jet-printing.pdf\">Temperature Influence on Ti3C2Tx Lines Printed by Aerosol Jet Printing<\/a><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">M. Borghetti, M. Serpelloni, E. Sardini, D. Spurling, V. Nicolosi<br><em>Sensors and Actuators A: Physical<\/em>, 332, 113185, 2021.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This work investigates the temperature-dependent electrical behavior of Aerosol Jet printed <strong>Ti3C2Tx MXene structures<\/strong>, contributing to the characterization of emerging functional materials for printed sensors.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>DOI:<\/strong> <a href=\"https:\/\/doi.org\/10.1016\/j.sna.2021.113185\">10.1016\/j.sna.2021.113185<\/a> | <strong><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Temperature-influence-on-Ti3C2Tx-lines-printed-by-aerosol-jet-printing.pdf\">Download PDF<\/a><\/strong><\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Evaluation_of_the_Curing_Process_Effects_on_the_TCR_of_Temperature_Sensors_Printed_by_Aerosol_Jet_Printing.pdf\">Evaluation of the Curing Process Effects on the TCR of Temperature Sensors Printed by Aerosol Jet Printing<\/a><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">T. Fapanni, H. Elbidweihy, D. Zappa, E. Comini, E. Sardini, M. Serpelloni<br><em>IEEE Sensors Journal<\/em>, 23, pp. 16625\u201316632, 2023.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The paper analyzes the influence of the curing process on the <strong>Temperature Coefficient of Resistance (TCR)<\/strong> of Aerosol Jet printed temperature sensors, highlighting the relationship between manufacturing conditions and sensor performance.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>DOI:<\/strong> <a href=\"https:\/\/doi.org\/10.1109\/JSEN.2023.3283797\">10.1109\/JSEN.2023.3283797<\/a> | <strong><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Evaluation_of_the_Curing_Process_Effects_on_the_TCR_of_Temperature_Sensors_Printed_by_Aerosol_Jet_Printing.pdf\">Download PDF<\/a><\/strong><\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/A_Feasibility_Study_of_Customized_and_Fully_Aerosol-Jet-Printed_Micro-Electrode_Arrays_for_In_Vitro_Application.pdf\">A Feasibility Study of Customized and Fully Aerosol-Jet-Printed Micro-Electrode Arrays for In Vitro Application<\/a><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">I. Armando, M. Borghetti, E. Sardini, M. Serpelloni<br><em>IEEE Sensors Journal<\/em>, 23, pp. 24205\u201324213, 2023.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This study demonstrates the design and additive fabrication of customized <strong>microelectrode arrays using Aerosol Jet Printing<\/strong>, showing the potential of the technology for biomedical and in-vitro sensing platforms.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>DOI:<\/strong> <a href=\"https:\/\/doi.org\/10.1109\/JSEN.2023.3313652\">10.1109\/JSEN.2023.3313652<\/a> | <strong><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/A_Feasibility_Study_of_Customized_and_Fully_Aerosol-Jet-Printed_Micro-Electrode_Arrays_for_In_Vitro_Application.pdf\">Download PDF<\/a><\/strong><\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Substrate_and_Coating_Effects_on_Temperature-Related_Behavior_of_Silver_Traces_Printed_by_Aerosol_Jet_for_Aerospace_Applications.pdf\">Substrate and Coating Effects on Temperature-Related Behavior of Silver Traces Printed by Aerosol Jet for Aerospace Applications<\/a><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">T. Fapanni, M. Serpelloni<br><em>IEEE Transactions on Instrumentation and Measurement<\/em>, 73, 2024.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This work investigates the influence of substrates and protective coatings on the temperature-dependent behavior of Aerosol Jet printed silver traces, with particular attention to demanding aerospace applications.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>DOI:<\/strong> <a href=\"https:\/\/doi.org\/10.1109\/TIM.2024.3476607\">10.1109\/TIM.2024.3476607<\/a> | <strong><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Substrate_and_Coating_Effects_on_Temperature-Related_Behavior_of_Silver_Traces_Printed_by_Aerosol_Jet_for_Aerospace_Applications.pdf\">Download PDF<\/a><\/strong><\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Preliminary-Characterization-of-a-Novel-Aerosol-Jet-Printed-Strain-Sensor-for-Feasibility-Assessment-in-a-Variable-Stiffness-Arterial-Simulator-Application.pdf\">Preliminary Characterization of a Novel Aerosol Jet-Printed Strain Sensor for Feasibility Assessment in a Variable Stiffness Arterial Simulator Application<\/a><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">F. Filippi, G. Fiori, A. Genovesi, M. Barletta, M. Lancini, M. Serpelloni, A. Scorza, S.A. Sciuto<br><em>Sensors<\/em>, 24, 7725, 2024.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The study characterizes an Aerosol Jet printed strain sensor and evaluates its feasibility for integration into a variable-stiffness arterial simulator.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>DOI:<\/strong> <a href=\"https:\/\/doi.org\/10.3390\/s24237725\">10.3390\/s24237725<\/a> | <strong><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Preliminary-Characterization-of-a-Novel-Aerosol-Jet-Printed-Strain-Sensor-for-Feasibility-Assessment-in-a-Variable-Stiffness-Arterial-Simulator-Application.pdf\">Download PDF<\/a><\/strong><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Related Conference Papers<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/doi.org\/10.1016\/j.procir.2022.06.018\">A Computational Model for the Design Optimization of Multi-Electrode Arrays by Aerosol-Jet Printing<\/a><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">I. Armando, M. Borghetti, E. Sardini, M. Serpelloni<br><em>Procedia CIRP<\/em>, 110, pp. 87\u201392, 2022.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A computational approach is proposed for the design and optimization of microelectrode arrays fabricated by Aerosol Jet Printing.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>DOI:<\/strong> <a href=\"https:\/\/doi.org\/10.1016\/j.procir.2022.06.018\">10.1016\/j.procir.2022.06.018<\/a><\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Uncertainty-Sources-in-Aerosol-Jet-Printed-and-Flexible-Electrochemical-Sensors.pdf\">Uncertainty Sources in Aerosol Jet Printed and Flexible Electrochemical Sensors<\/a><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">T. Fapanni, M. Serpelloni, E. Sardini<br><em>2022 IEEE International Workshop on Metrology for Industry 4.0 and IoT<\/em>, 2022.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This contribution investigates uncertainty sources associated with the fabrication and characterization of flexible sensors produced by Aerosol Jet Printing.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>DOI:<\/strong> <a href=\"https:\/\/doi.org\/10.1109\/MetroInd4.0IoT54413.2022.9831522\">10.1109\/MetroInd4.0IoT54413.2022.9831522<\/a> | <strong><a href=\"https:\/\/mauro-serpelloni.unibs.it\/wp-content\/uploads\/Uncertainty-Sources-in-Aerosol-Jet-Printed-and-Flexible-Electrochemical-Sensors.pdf\">Download PDF<\/a><\/strong><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Related Research Areas<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Applications of additive manufacturing to <strong>printed resistive and capacitive sensors, flexible electronics and smart objects<\/strong> are presented in <strong>Printed and Flexible Electronics<\/strong>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Applications involving <strong>electrochemical sensing, biosensors and ion-selective electrodes<\/strong> are presented in <strong>Printed Electrochemical, Biosensors and Ion-Selective Sensors<\/strong>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A complete list of journal articles and conference papers is available in the <strong>Publications<\/strong> section.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Aerosol Jet Printing (AJP) is an additive manufacturing technology capable of depositing functional materials with micrometric resolution on planar, flexible and three-dimensional substrates. Our research focuses on the use of Aerosol Jet Printing and other direct-write additive manufacturing technologies for the fabrication of sensors and electronic devices, with particular attention to process optimization, functional materials, &#8230; <a title=\"Aerosol Jet Printing and Additive Manufacturing of Sensors\" class=\"read-more\" href=\"https:\/\/mauro-serpelloni.unibs.it\/index.php\/research-areas\/aerosol-jet-printing-and-additive-manufacturing-of-sensors\/\" aria-label=\"Read more about Aerosol Jet Printing and Additive Manufacturing of Sensors\">Read more<\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"parent":10,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":""},"class_list":["post-160","page","type-page","status-publish"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Aerosol Jet Printing and Additive Manufacturing of Sensors - 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