The effect of water ingress on additively manufactured electrodes

Additive Manufacturing (AM), otherwise known as 3D printing, is becoming increasingly popular in the field of electrochemistry since it allows affordable, on-demand production of bespoke devices. Provided a suitably conductive polymer composite material is used, this can include working electrodes. However, while a number of publications have shown such Additively Manufactured Electrodes (AMEs) to be effective, there remain several fundamental areas which must be understood to continue the development of AM for electrochemistry. One such area is the effect of solvent ingress on AME performance, with water probably representing the most important solvent for study considering the amount of electrochemical sensing directed towards biological and environmental systems. Therefore, in this work we study the effect of up to 28 days of water immersion on the physical properties and electrochemical performance of AMEs made from a commonly used conductive material, Protopasta. It is shown that water immersion leads to water uptake of around 1-1.5% by mass for our specific electrode design, which in turn causes a decrease in measured peak current, but an increase in the heterogeneous electron transfer rate constant, k0. These observations are rationalised in terms of Ohmic drop and conductive filler surface chemistry, respectively. Overall, it can be concluded that water ingress is likely to be a concern for any application where AMEs are expected to have extended contact with water, although we note that more work is required to fully understand the extent of the issue

Circular economy electrochemistry: recycling old mixed material additively manufactured sensors into new electroanalytical sensing platforms

Recycling used mixed material additively manufactured electroanalytical sensors into new 3D-printing filaments (both conductive and non-conductive) for the production of new sensors is reported herein. Additively manufactured (3D-printed) sensing platforms were transformed into a non-conductive filament for fused filament fabrication through four different methodologies (granulation, ball-milling, solvent mixing, and thermal mixing) with thermal mixing producing the best quality filament, as evidenced by the improved dispersion of fillers throughout the composite. Utilizing this thermal mixing methodology, and without supplementation with the virgin polymer, the filament was able to be cycled twice before failure. This was then used to process old sensors into an electrically conductive filament through the addition of carbon black into the thermal mixing process. Both recycled filaments (conductive and non-conductive) were utilized to produce a new electroanalytical sensing platform, which was tested for the cell's original application of acetaminophen determination. The fully recycled cell matched the electrochemical and electroanalytical performance of the original sensing platform, achieving a sensitivity of 22.4 ± 0.2 μA μM-1, a limit of detection of 3.2 ± 0.8 μM, and a recovery value of 95 ± 5% when tested using a real pharmaceutical sample. This study represents a paradigm shift in how sustainability and recycling can be utilized within additively manufactured electrochemistry toward promoting circular economy electrochemistry