Inkjet fabrication processes for large area nanostructured strain sensors

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This project targets the development of a near-net-shape fabrication process based on inkjet micropatterning of nanostructured composites. It addresses Canada's need for alternative low-cost competitive and green manufacturing methods. The technology will enable the inexpensive manufacturing of high performance sensors for structural health monitoring (SHM) of bridges, concrete structures, pipelines or other critical infrastructure. The current lack of affordable SHM of critical infrastructure has been linked to a loss in GDP of 1%. Inkjet micropatterning enables the fabrication of microdevices by drop-on-demand deposition of a wide variety of materials (polymers, solvents, functional composites containing nanowires and nanotubes, etc.) in the form of "inks" for non-contact patterning onto rigid, flexible, rough, smooth, and 3-D substrates and is capable of producing very large area devices at low-cost. The process is accurate, relatively high resolution (10-100µm), and high speed. It is also an example of green manufacturing since the process consumes very little material and produces little waste. New processes will be developed, where inkjet micropatterning is used in conjunction with an innovative hydrodynamic technique for controlled alignment of printed nanotubes and nanowires. Their alignment maximizes the intrinsic giant piezoresistive effect in carbon nanotubes and the giant piezoelectric effect in semiconductor nanowires. This technique will enable the manufacturing of novel strain sensing devices with sensitivities two orders of magnitude greater than conventional strain gauges. In addition, the higher zero-stress resistance of the printed structures results in lower power consumption and less influence from the resistance in the lead wires. The mechanical and chemical stability of carbon nanotubes and metal oxide nanowires will improve the long-term stability of the devices. In addition to SHM, the underlying fabrication technology will serve as a platform for exploring many other sensing applications.