3D-Printed Electrochemical Sensor for Rapid Detection of Phenolic Oxidation Products Relevant to Organic Aerosol Formation

Phenolic compounds are key precursors and intermediates in the formation and aging of secondary organic aerosols (SOA), particularly in biomass-burning plumes and urban atmospheres. However, their detection typically requires laboratory-based chromatographic or mass-spectrometric techniques, limiting rapid or on-site characterization. The current research present a fully 3D-printed electrode (3D-PE) platform produced via hybrid material extrusion additive manufacturing, providing a compact, low-cost, and field-deployable tool for electrochemical quantification of atmospheric phenolics. The device integrates PLA-based structural components with graphene and silver conductive layers deposited in a single manufacturing step. Cyclic voltammetry measurements demonstrate clear and distinct redox signatures for representative phenolic structures, with oxidation potentials of 0.48–0.68 V and well-resolved reduction peaks. These redox behaviors correspond to functional groups commonly found in lignin-derived and anthropogenically emitted aromatic species.

The 3D-PE operates with sample volumes as low as 50 µL, suitable for extracts from aerosol filters, cloud water, or fog samples. Its electroactive surface area (5.8–6.7 mm²) and high electron-transfer efficiency from the graphene electrode enable sensitive detection of trace phenolic compounds. The platform’s portability and rapid response offer new opportunities for quantifying oxidation intermediates during field campaigns, studying heterogeneous oxidation pathways, and investigating Secondary Organic Aerosol (SOA) formation dynamics.

This work demonstrates that additive manufacturing provides a promising route for developing next-generation, customizable atmospheric chemistry sensors. The 3D-printed electrochemical platform can complement established mass-spectrometric techniques by enabling low-cost, high-frequency measurements of reactive organic compounds that play central roles in SOA formation and atmospheric oxidative chemistry.