Enhancing the Performance of Planar SERS Sensors with Pyroelectrohydrodynamic Jet Printing

An alternative method for fabricating planar surface-enhanced Raman spectroscopy (SERS) sensors, offering enhanced performance compared to conventional drop-casting techniques, is presented. We synthesized stable gold nanoparticles (AuNPs) with an average diameter of 16 ± 2 nm and developed two types of SERS sensors using pyro-electrohydrodynamic jet printing (p-jet) technology. The first sensor, printed on a glass substrate, featured a corona pattern with sensing areas aligned to the laser spot size, enabling efficient sampling with minimal material waste. The second sensor, fabricated on a dithiol-functionalized gold substrate, demonstrated uniform nanoparticle coverage. SERS activity was evaluated using p-Mercaptoaniline (pMA), yielding intense and reproducible spectra. Raman imaging confirmed consistent SERS activity, uniform nanoparticle distribution, and sensor stability. Statistical analysis indicated high reproducibility in sensor dimensions and shapes, underscoring the potential of p-jet microprinting as a cost-effective, stable, and scalable method for producing high-performance SERS sensors suitable for diverse applications.