Synthesis and evaluation of PEDOT:PSS-based inks for inkjet-printed carbon microstructures for C-MEMS applications

Inkjet printing has emerged as a promising alternative for microfabrication, offering mask-free, rapid, and material-efficient patterning. While inkjet-compatible formulations are widely used for the fabrication of electronic devices, their potential as carbon precursors for Carbon Microelectromechanical Systems (C-MEMS) remains largely unexplored. Additionally, access to commercial inks can be limited in certain regions, posing challenges for researchers seeking to implement this technology. To overcome these limitations, this study investigates the formulation of five PEDOT:PSS-derived carbon precursor inks. These formulations were synthesized and evaluated based on viscosity, surface tension, and wettability to determine their printability. Among them, two inks met the necessary rheological criteria and were successfully printed into rectangular patterns, which were subsequently pyrolyzed at 900 °C. Morphological analysis using SEM and optical profilometry revealed that one of the printed features exhibited a shrinkage of 63.97 % following pyrolysis, decreasing from 26.83 ± 7.53 nm to 9.66 ± 1.36 nm. Electrical characterization further demonstrated an 80 % reduction in resistivity, from 46.61 ± 16.98 Ω·cm to 8.76 ± 0.59 Ω·cm. Raman spectroscopy confirmed the formation of glass-like carbon structures in both pyrolyzed inks. Collectively, these results highlight the potential of the formulated PEDOT:PSS-based inks as a viable and accessible alternatives to commercially available options for inkjet-printed C-MEMS applications. • Synthesis of alternative printable PEDOT:PSS ink for Inkjet technology. • Evaluation of rheological properties to ensure Inkjet printability. • Fabrication of well-defined geometric shapes via Inkjet. • Assessment of stable carbon structures after pyrolysis.