Additive-free graphene-based inks for 3D printing functional conductive aerogels

This study demonstrates an all-graphene, additive-free, aqueous-based ink for direct ink writing (DIW) to 3D-print functional aerogels for applications in electronics and electromagnetic interference (EMI) shields. We employ a two-step electrochemical method with a specially designed intercalation step that controls the surface functionality of graphene nanosheets. Comprehensive characterization reveals the significant impact of the physicochemical properties of graphene nanosheets on homogeneity, rheology, electrical conductivity, and EMI shielding effectiveness (SE). A critical observation is that rheology alone is insufficient to predict the printability of two-dimensional particulate systems, while ink homogeneity, dictated by inter-sheet interactions, plays a vital role. By focusing on optimizing intercalation conditions, we find that phosphoric acid treatment is most effective in enhancing both printability and conductivity, achieving an electrical conductivity of 158 S cm⁻¹ and an EMI SE of 50 dB (at 50 μm thickness) without requiring any post-processing reduction. Systematic experiments with varying durations of phosphoric acid intercalation establish that a 10-minutes treatment produces inks with superior 3D printing fidelity. This innovative approach to graphene ink production enables rapid, continuous, and large-scale manufacturing of lightweight, porous materials, avoiding the need for environmentally harmful reductant chemistries or high-temperature processing. Furthermore, eliminating the reduction step in the fabrication process aligns with industrial demands for energy-efficient production processes and high output rates, marking a significant advancement in the field of materials science and offering promising prospects for applying graphene-based inks in advanced manufacturing technologies.