Sustainable Production of Biomass-Derived Graphite and Graphene Conductive Inks from Biochar.

Graphite is a commonly used raw material across many industries and the demand for high-quality graphite has been increasing in recent years, especially as a primary component for lithium-ion batteries. However, graphite production is currently limited by production shortages, uneven geographical distribution, and significant environmental impacts incurred from conventional processing. Here, an efficient method of synthesizing biomass-derived graphite from biochar is presented as a sustainable alternative to natural and synthetic graphite. The resulting bio-graphite equals or exceeds quantitative quality metrics of spheroidized natural graphite, achieving a Raman ID/IG ratio of 0.051 and crystallite size parallel to the graphene layers (La) of 2.08 µm. This bio-graphite is directly applied as a raw input to liquid-phase exfoliation of graphene for the scalable production of conductive inks. The spin-coated films from the bio-graphene ink exhibit the highest conductivity among all biomass-derived graphene or carbon materials, reaching 3.58 ± 0.16 × 104 S m-1. Life cycle assessment demonstrates that this bio-graphite requires less fossil fuel and produces reduced greenhouse gas emissions compared to incumbent methods for natural, synthesized, and other bio-derived graphitic materials. This work thus offers a sustainable, locally adaptable solution for producing state-of-the-art graphite that is suitable for bio-graphene and other high-value products.

Bayesian Optimization of Environmentally Sustainable Graphene Inks Produced by Wet Jet Milling.

Liquid phase exfoliation (LPE) of graphene is a potentially scalable method to produce conductive graphene inks for printed electronic applications. Among LPE methods, wet jet milling (WJM) is an emerging approach that uses high-speed, turbulent flow to exfoliate graphene nanoplatelets from graphite in a continuous flow manner. Unlike prior WJM work based on toxic, high-boiling-point solvents such as n-methyl-2-pyrollidone (NMP), this study uses the environmentally friendly solvent ethanol and the polymer stabilizer ethyl cellulose (EC). Bayesian optimization and iterative batch sampling are employed to guide the exploration of the experimental phase space (namely, concentrations of graphite and EC in ethanol) in order to identify the Pareto frontier that simultaneously optimizes three performance criteria (graphene yield, conversion rate, and film conductivity). This data-driven strategy identifies vastly different optimal WJM conditions compared to literature precedent, including an optimal loading of 15 wt% graphite in ethanol compared to 1 wt% graphite in NMP. These WJM conditions provide superlative graphene production rates of 3.2 g hr-1 with the resulting graphene nanoplatelets being suitable for screen-printed micro-supercapacitors. Finally, life cycle assessment reveals that ethanol-based WJM graphene exfoliation presents distinct environmental sustainability advantages for greenhouse gas emissions, fossil fuel consumption, and toxicity.

Analysis of DNA Origami Nanostructures Using Capillary Electrophoresis.

DNA origami nanostructures are engineered nanomaterials (ENMs) that possess significant customizability, biocompatibility, and tunable structural and functional properties, making them potentially useful materials in fields, such as medicine, biocomputing, biomedical engineering, and measurement science. Despite the potential of DNA origami as a functional nanomaterial, a major barrier to its applicability is the difficulty associated with obtaining pure, well-folded structures. Therefore, rapid methods of analysis to ensure purity are needed to support the rapid development of this class of nanomaterials. Here, we present the development of capillary electrophoresis (CE) as an analytical tool for DNA origami. CE was investigated under both capillary zone electrophoresis (CZE) and capillary transient isotachophoresis (ctITP) modes. Optimization of both systems yielded baseline resolved separations of folded DNA origami nanostructures from excess staple strands. The ctITP separation mode demonstrated superior performance in terms of peak resolution (Rs = 2.05 ± 0.3), peak efficiency (N = 12,200 ± 230), and peak symmetry (As = 1.29 ± 0.032). The SYBR family dyes (Gold, Green I, and Green II) were investigated as highly efficient, noncovalent fluorophores for on-column labeling of DNA origami and detection using laser-induced fluorescence. Finally, ctITP analysis conditions were also applied to DNA origami nanostructures with different shapes and for the differentiation of DNA origami aggregates.

In Situ Quantification of Silver Nanoparticle Dissolution Kinetics in Simulated Sweat Using Linear Sweep Stripping Voltammetry.

Linear sweep stripping voltammetry (LSSV) is demonstrated as a sensitive, rapid, and cost-efficient analytical technique for the quantification of silver nanoparticle (AgNP) dissolution rates in simulated sweat. LSSV does not require the extensive sample preparation (e.g., ultrafiltration or centrifugation) needed by more commonly employed techniques, such as atomic spectroscopy. The limit of detection (LOD) of Ag(I)(aq) was 14 ± 6 µg L-1, and measured dissolution rate constants, kdissolution, varied from 0.0168-0.1524 h-1, depending on solution conditions. These values are comparable and agree well with those determined by others in the literature using atomic spectroscopy. Importantly, LSSV had the necessary sensitivity to distinguish the effects of SSW solution conditions on AgNP dissolution rates. Specifically, enhanced dissolution rates were observed with decreased pH and with increased NaCl concentration. The colloidal stability of AgNPs in SSW solutions was also characterized using dynamic light scattering (DLS), ζ potential, and quantitative UV-vis spectroscopy measurements. An increase in AgNP aggregation rate was observed with increased NaCl concentration in SSW, suggesting that the enhancement in AgNP dissolution is driven by the large Cl/Ag ratio, even as the AgNPs undergo significant aggregation.

Ultrahigh-throughput cross-flow filtration of solution-processed 2D materials enabled by porous ceramic membranes.

Printed electronics is a disruptive technology in multiple applications including environmental and biological sensors, flexible displays, and wearable diagnostic devices. With superlative electronic, optical, mechanical, and chemical properties, two-dimensional (2D) materials are promising candidates for printable electronic inks. While liquid-phase exfoliation (LPE) methods can produce electronic-grade 2D materials, conventional batch separation processes typically rely on centrifugation, which requires significant time and effort to remove incompletely exfoliated bulk powders, hindering the scale-up of 2D ink manufacturing. While cross-flow filtration (CFF) has emerged as a promising continuous flow separation method for solution-processed 2D nanosheets, previously demonstrated polymer CFF membranes necessitate low 2D nanosheet concentrations to avoid fouling, which ultimately limits mass throughput. Here, we demonstrate a fully flow-based, exfoliation-to-ink system for electronic-grade 2D materials using an integrated cross-flow separation and concentration system. To overcome the relatively low-throughput processing concentrations of incumbent polymer CFF membranes, we employ porous ceramic CFF membranes that are tolerant to 10-fold higher nanosheet concentrations and flow rates without compromising separation efficiency. Furthermore, we demonstrate a concentration method via cross-flow ultrafiltration, where the retentate can be directly formulated into printable inks with electronic-grade performance that meets or exceeds centrifugally produced inks. Life cycle assessment and technoeconomic analysis quantitatively confirm the advantages of ceramic versus polymer CFF membranes including reductions of 97%, 96%, 94%, and 93% for greenhouse gas emissions, water consumption, fossil fuel consumption, and specific production costs, respectively. Overall, this work presents an environmentally sustainable and cost-effective solution for the fabrication, separation, and printing of electronic-grade 2D materials.

Biolayer-Interferometry-Guided Functionalization of Screen-Printed Graphene for Label-Free Electrochemical Virus Detection.

Additive manufacturing holds promise for rapid prototyping and low-cost production of biosensors for diverse pathogens. Among additive manufacturing methods, screen printing is particularly desirable for high-throughput production of sensing platforms. However, this technique needs to be combined with carefully formulated inks, rapid postprocessing, and selective functionalization to meet all requirements for high-performance biosensing applications. Here, we present screen-printed graphene electrodes that are processed with thermal annealing to achieve high surface area and electrical conductivity for sensitive biodetection via electrochemical impedance spectroscopy. As a proof-of-concept, this biosensing platform is utilized for electrochemical detection of SARS-CoV-2. To ensure reliable specificity in the presence of multiple variants, biolayer interferometry (BLI) is used as a label-free and dynamic screening method to identify optimal antibodies for concurrent affinity to the Spike S1 proteins of Delta, Omicron, and Wild Type SARS-CoV-2 variants while maintaining low affinity to competing pathogens such as Influenza H1N1. The BLI-identified antibodies are robustly bound to the graphene electrode surface via oxygen moieties that are introduced during the thermal annealing process. The resulting electrochemical immunosensors achieve superior metrics including rapid detection (55 s readout following 15 min of incubation), low limits of detection (approaching 500 ag/mL for the Omicron variant), and high selectivity toward multiple variants. Importantly, the sensors perform well on clinical saliva samples detecting as few as 103 copies/mL of SARS-CoV-2 Omicron, following CDC protocols. The combination of the screen-printed graphene sensing platform and effective antibody selection using BLI can be generalized to a wide range of point-of-care immunosensors.

Biorenewable Exfoliation of Electronic-Grade Printable Graphene Using Carboxylated Cellulose Nanocrystals.

The absence of scalable and environmentally sustainable methods for producing electronic-grade graphene nanoplatelets remains a barrier to the industrial-scale application of graphene in printed electronics and conductive composites. To address this unmet need, here we report the utilization of carboxylated cellulose nanocrystals (CNCs) extracted from the perennial tall grass Miscanthus × giganteus as a biorenewable dispersant for the aqueous liquid-phase exfoliation of few-layer graphene nanoplatelets. This CNC-based exfoliation procedure was optimized using a Bayesian machine learning model, resulting in a significant graphite-to-graphene conversion yield of 13.4% and a percolating graphene thin-film electrical conductivity of 3.4 × 104 S m-1. The as-exfoliated graphene dispersions were directly formulated into an aerosol jet printing ink using cellulose-based additives to achieve high-resolution printing (∼20 µm line width). Life cycle assessment of this CNC-based exfoliation method showed substantial improvements for fossil fuel consumption, greenhouse gas emissions, and water consumption compared to incumbent liquid-phase exfoliation methods for electronic-grade graphene nanoplatelets. Mechanistically, potential mean force calculations from molecular dynamics simulations reveal that the high exfoliation yield can be traced back to the favorable surface interactions between CNCs and graphene. Ultimately, the use of biorenewable CNCs for liquid-phase exfoliation will accelerate the scalable and eco-friendly manufacturing of graphene for electronically conductive applications.

Fully Printed, High-Temperature Micro-Supercapacitor Arrays Enabled by a Hexagonal Boron Nitride Ionogel Electrolyte.

The proliferation and miniaturization of portable electronics require energy-storage devices that are simultaneously compact, flexible, and amenable to scalable manufacturing. In this work, mechanically flexible micro-supercapacitor arrays are demonstrated via sequential high-speed screen printing of conductive graphene electrodes and a high-temperature hexagonal boron nitride (hBN) ionogel electrolyte. By combining the superlative dielectric properties of 2D hBN with the high ionic conductivity of ionic liquids, the resulting hBN ionogel electrolyte enables micro-supercapacitors with exceptional areal capacitances that approach 1 mF cm-2 . Unlike incumbent polymer-based electrolytes, the high-temperature stability of the hBN ionogel electrolyte implies that the printed micro-supercapacitors can be operated at unprecedentedly high temperatures up to 180 °C. These elevated operating temperatures result in increased power densities that make these printed micro-supercapacitors particularly promising for applications in harsh environments such as underground exploration, aviation, and electric vehicles. The combination of enhanced functionality in extreme conditions and high-speed production via scalable additive manufacturing significantly broadens the technological phase space for on-chip energy storage.

Centrifuge-Free Separation of Solution-Exfoliated 2D Nanosheets via Cross-Flow Filtration.

Solution-processed graphene is a promising material for numerous high-volume applications including structural composites, batteries, sensors, and printed electronics. However, the polydisperse nature of graphene dispersions following liquid-phase exfoliation poses major manufacturing challenges, as incompletely exfoliated graphite flakes must be removed to achieve optimal properties and downstream performance. Incumbent separation schemes rely on centrifugation, which is highly energy-intensive and limits scalable manufacturing. Here, cross-flow filtration (CFF) is introduced as a centrifuge-free processing method that improves the throughput of graphene separation by two orders of magnitude. By tuning membrane pore sizes between microfiltration and ultrafiltration length scales, CFF can also be used for efficient recovery of solvents and stabilizing polymers. In this manner, life cycle assessment and techno-economic analysis reveal that CFF reduces greenhouse gas emissions, fossil energy usage, water consumption, and specific production costs of graphene manufacturing by 57%, 56%, 63%, and 72%, respectively. To confirm that CFF produces electronic-grade graphene, CFF-processed graphene nanosheets are formulated into printable inks, leading to state-of-the-art thin-film conductivities exceeding 104 S m-1 . This CFF methodology can likely be generalized to other van der Waals layered solids, thus enabling sustainable manufacturing of the diverse set of applications currently being pursued for 2D materials.

Sterilizable and Reusable UV-Resistant Graphene-Polyurethane Elastomer Composites.

Shortages of personal protective equipment (PPE) at the start of the COVID-19 pandemic caused medical workers to reuse medical supplies such as N95 masks. While ultraviolet germicidal irradiation (UVGI) is commonly used for sterilization, UVGI can also damage the elastomeric components of N95 masks, preventing effective fit and thus weakening filtration efficacy. Although PPE shortage is no longer an acute issue, the development of sterilizable and reusable UV-resistant elastomers remains of high interest from a long-term sustainability and health perspective. Here, graphene nanosheets, produced by scalable and sustainable exfoliation of graphite in ethanol using the polymer ethyl cellulose (EC), are utilized as UV-resistant additives in polyurethane (PU) elastomer composites. By increasing the graphene/EC loading up to 1 wt %, substantial UV protection is imparted by the graphene nanosheets, which strongly absorb UV light and hence suppress photoinduced degradation of the PU matrix. Additionally, graphene/EC provides mechanical reinforcement, such as increasing Young's modulus, elongation at break, and toughness, with negligible changes following UV exposure. These graphene/EC-PU composites remain mechanically robust over at least 150 sterilization cycles, enabling safe reuse following UVGI. Beyond N95 masks, these UVGI-compatible graphene/EC-PU composites have potential utility in other PPE applications to address the broader issue of single-use waste.