Development of a Gold Nanoparticle Dispersion for Plasma Jet Printing on Solid Substrates

Gold nanoparticles (AuNPs) were synthesised using ultrasonic spray pyrolysis (USP) with the addition of polyvinylpyrrolidone (PVP) as a stabilising agent and subsequently dried via lyophilisation. The resulting dried AuNPs were redispersed in ethanol and homogenised to ensure uniform dispersion. This AuNP dispersion was then deposited onto a ceramic substrate—aluminum oxide (Al2O3)—using plasma jet printing. Comprehensive characterisation of the dispersion, AuNPs, and the resulting printed lines was performed using the following methods: inductively coupled plasma optical emission spectroscopy (ICP-OES), scanning electron microscopy (SEM), transmission electron microscopy (TEM), selected area electron diffraction (SAED), scanning transmission electron microscopy (STEM), energy dispersive X-ray spectroscopy (EDS), ultraviolet-visible spectroscopy (UV-Vis), dynamic light scattering (DLS), measurements of dispersion viscosity and printed line roughness. ICP-OES confirmed consistent gold content in the AuNP dispersion, while the SEM and EDS analyses revealed predominantly spherical AuNPs with minimal aggregation and similar size distributions. TEM, SAED, and STEM/EDS confirmed that the crystalline structure and elemental composition of the AuNPs had diverse morphologies and strong gold signals. The UV-Vis, DLS, and zeta potential measurements indicated moderate colloidal stability, and thermogravimetric analysis (TGA) verified the AuNPs dispersion’s composition. The AuNP dispersion exhibited thixotropic behaviour favourable for printing applications, while confocal microscopy confirmed smooth, uniform printed traces, with an average surface line roughness of 1.65 µm. The successful use of plasma printing with the AuNP dispersion highlights its potential for functional material applications in electronics.