Pd-Modified Microneedle Array Sensor Integration with Deep Learning for Predicting Silica Aerogel Properties in Real Time

The continuous global effort to predict material properties through artificial intelligence has predominantly focused on utilizing material stoichiometry or structures in deep learning models. This study aims to predict material properties using electrochemical impedance data, along with frequency and time parameters, that can be obtained during processing stages. The target material, silica aerogel, is widely recognized for its lightweight structure and excellent insulating properties, which are attributed to its large surface area and pore size. However, production is often delayed due to the prolonged aging process. Real-time prediction of material properties during processing can significantly enhance process optimization and monitoring. In this study, we developed a system to predict the physical properties of silica aerogel, specifically pore diameter, pore volume, and surface area. This system integrates a 3 × 3 array Pd/Au sensor, which exhibits high sensitivity to varying pH levels during aerogel synthesis and is capable of acquiring a large data set (impedance, frequency, time) in real-time. The collected data is then processed through a deep neural network algorithm. Because the system is trained with data obtained during the processing stage, it enables real-time predictions of the critical properties of silica aerogel, thus facilitating process optimization and monitoring. The final performance evaluation demonstrated an optimal alignment between true and predicted values for silica aerogel properties, with a mean absolute percentage error of approximately 0.9%. This approach holds great promise for significantly improving the efficiency and effectiveness of silica aerogel production by providing accurate real-time predictions.