Design of Experiments and Optimization of Laser-Induced Graphene.

Realization of graphene-based sensors and electronic devices remains challenging, in part due to integration challenges with current fabrication and manufacturing processes. Thus, scalable methods for in situ fabrication of high-quality graphene-like materials are essential. Low-cost CO2 laser engravers can be used for site-selective conversion of polyimide under ambient conditions to create 3-D, rotationally disordered, few-layer, porous, graphene-like electrodes. However, the influences of non-linear parameter terms and interactions between key parameters on the graphitization process present challenges for rapid, resource-efficient optimization. An iterative optimization strategy was developed to identify promising regions in parameter space for two key parameters, laser power and scan speed, with the goal of optimizing electrode performance while maximizing scan speed and hence fabrication throughput. The strategy employed iterations of Design of Experiments Response Surface (DoE-RS) methods combined with choices of readily measurable parameters to minimize measurement resources and time. The initial DoE-RS experiment set employed visual response parameters, while subsequent iterations used sheet resistance as the optimization parameter. The final model clearly demonstrates that laser graphitization through raster scanning is a highly non-linear process requiring polynomial terms in scan speed and laser power up to fifth order. Two regions of interest in parameter space were identified using this strategy: Region 1 represents the global minimum for sheet resistance for this laser (∼16 Ω/sq), found at a low scan speed (70 mm/s) and a low average power (2.1 W) . Region 2 is a local minimum for sheet resistance (36 Ω/sq), found at higher values for scan speed (340 mm/s) and average power (3.4 W), allowing ∼5-fold reduction in write time. Importantly, these minima do not correspond to constant ratios of average laser power to scan speed. This highlights the benefits of DoE-RS methods in rapid identification of optimum parameter combinations that would be difficult to discover using traditional one-factor-at-a-time optimization. Verification data from Raman spectroscopy showed sharp 2D peaks with mean full-width-at-half-maximum intensity values <80 cm-1 for both regions, consistent with high-quality 3D graphene-like carbon. Graphene-based electrodes fabricated using the parameters from the respective regions yielded similar performance when employed as capacitive humidity sensors with hygroscopic dielectric layers. Devices fabricated using Region 1 parameters (16 Ω/sq) yielded capacitance responses of 0.78 ± 0.04 pF at 0% relative humidity (RH), increasing to 31 ± 7 pF at 85.1% RH. Region 2 devices (36 Ω/sq) showed comparable responses (0.88 ± 0.04 pF at 0% RH, 28 ± 5 pF at 85.1% RH).

Fabrication and Electrochemical Properties of Three-Dimensional (3D) Porous Graphitic and Graphenelike Electrodes Obtained by Low-Cost Direct Laser Writing Methods.

The development of three-dimensional (3D) porous graphitic structures is of great interest for electrochemical sensing applications as they can support fast charge transfer and mass transport through their extended, large surface area networks. In this work, we present the facile fabrication of conductive and porous graphitic electrodes by direct laser writing techniques. Irradiation of commercial polyimide sheets (Kapton tape) was performed using a low-cost laser engraving machine with visible excitation wavelength (405 nm) at low power (500 mW), leading to formation of 3D laser-induced graphene (LIG) structures. Systematic correlation between applied laser dwell time per pixel ("dwell time") and morphological/structural properties of fabricated electrodes showed that conductive and highly 3D porous structures with spectral signatures of nanocrystalline graphitic carbon materials were obtained at laser dwell times between 20 and 110 ms/pix, with graphenelike carbon produced at 50 ms/pix dwell time, with comparable properties to LIG obtained with high cost CO2 lasers. Electrochemical characterization with inner and outer sphere mediators showed fast electron transfer rates, comparable to previously reported 2D/3D graphene-based materials and other graphitic carbon electrodes. This work opens the way to the facile fabrication of low-cost, disposable electrochemical sensor platforms for decentralized assays.

Asymmetric Pentagonal Metal Meshes for Flexible Transparent Electrodes and Heaters.

Metal meshes have emerged as an important class of flexible transparent electrodes. We report on the characteristics of a new class of asymmetric meshes, tiled using a recently discovered family of pentagons. Micron-scale meshes were fabricated on flexible polyethylene terephthalate substrates via optical lithography, metal evaporation (Ti 10 nm, Pt 50 nm), and lift-off. Three different designs were assessed, each with the same tessellation pattern and line width (5 µm), but with different sizes of the fundamental pentagonal unit. Good mechanical stability was observed for both tensile strain and compressive strain. After 1000 bending cycles, devices subjected to tensile strain showed fractional resistance increases in the range of 8-17%, while devices subjected to compressive strain showed fractional resistance increases in the range of 0-7%. The performance of the pentagonal metal mesh devices as visible transparent heaters via Joule heating was also assessed. Rapid response times (∼15 s) at low bias voltage (≤5 V) and good thermal resistance characteristics (213-258 °C cm2/W) were found using measured thermal imaging data. Deicing of an ice-bearing glass coupon on top of the transparent heater was also successfully demonstrated.

Low-cost silver capped polystyrene nanotube arrays as super-hydrophobic substrates for SERS applications.

In this paper, we describe the fabrication, simulation and characterization of dense arrays of freestanding silver capped polystyrene nanotubes, and demonstrate their suitability for surface enhanced Raman scattering (SERS) applications. Substrates are fabricated in a rapid, low-cost and scalable way by melt wetting of polystyrene (PS) in an anodized alumina (AAO) template, followed by silver evaporation. Scanning electron microscopy reveals that substrates are composed of a dense array of freestanding polystyrene nanotubes topped by silver nanocaps. SERS characterization of the substrates, employing a monolayer of 4-aminothiophenol (4-ABT) as a model molecule, exhibits an enhancement factor of ∼1.6 × 10(6), in agreement with 3D finite difference time domain simulations. Contact angle measurements of the substrates revealed super-hydrophobic properties, allowing pre-concentration of target analyte into a small volume. These super-hydrophobic properties of the samples are taken advantage of for sensitive detection of the organic pollutant crystal violet, with detection down to ∼400 ppt in a 2 µl aliquot demonstrated.

Mechanical constraint and release generates long, ordered horizontal pores in anodic alumina templates.

We describe the formation of long, highly ordered arrays of planar oriented anodic aluminum oxide (AAO) pores during plane parallel anodization of thin aluminum 'finger' microstructures fabricated on thermally oxidized silicon substrates and capped with a silicon oxide layer. The pore morphology was found to be strongly influenced by mechanical constraint imposed by the oxide layers surrounding the Al fingers. Tractions induced by the SiO(2) substrate and capping layer led to frustrated volume expansion and restricted oxide flow along the interface, with extrusion of oxide into the primary pore volume, leading to the formation of dendritic pore structures and meandering pore growth. However, partial relief of the constraint by a delaminating interfacial fracture, with its tip closely following the anodization front, led to pore growth that was highly ordered with regular, hexagonally packed arrays of straight horizontal pores up to 3 µm long. Detailed characterization of both straight and dendritic planar pores over a range of formation conditions using advanced microscopy techniques is reported, including volume reconstruction, enabling high quality 3D visualization of pore formation.

Routes to regioselective deuteriation of heteroaromatic compounds.

A systematic approach to the deuteriation of polypyridyl type ligands is reported. A range of isotopologues of heteroaromatic compounds containing pyrazyl, pyridyl, 1,2,4-triazole, thienyl, methyl, and phenyl moieties, have been prepared in a cost-effective manner, using a range of methods based on subcritical aqueous media. Selectively and fully deuteriated ligands are characterized by mass spectrometry and(1)H, (2)D, and (13)C NMR spectroscopy. The application of deuteriation to supramolecular chemistry is discussed.