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Electrochemical sensing techniques rely on redox reactions taking place at the electrode surface. The configuration of this surface is of the utmost importance in the advancement of electrochemical sensors. The majority of previous electrode manufacturing methods, including 3D printing have produced electrodes with flat surfaces. There is a distinct potential for 3D printing to create intricate and distinctive electrode surface shapes. In the proposed work, 3D printed carbon black polylactic acid electrodes with nine different surface morphologies were made. These were compared to a flat surface electrode. To evaluate the performance of the electrodes, measurements were conducted in three different redox probes (ferrocene methanol, ferricyanide, and dopamine). Our findings highlighted that when electrodes were normalised for the geometric surface area of the electrode, the surface pattern of the electrode surface can impact the observed current and electron transfer kinetics. Electrodes that had a dome and flag pattern on the electrode surface showed the highest oxidation currents and had lower values for the difference between the anodic and cathodic peak current (Δ E ). However, designs with rings had lower current values and higher Δ E values. These differences are most likely due to variations in the accessibility of conductive sites on the electrode surface due to the varying surface roughness of different patterned designs. Our findings highlight that when making electrodes using 3D printing, surface patterning of the electrode surface can be used as an effective approach to enhance the performance of the sensor for varying applications.

Additive manufacturing also known as 3D printing is being utilised in electrochemistry to reproducibly develop complex geometries with conductive properties. In this study, we explored if the electrochemical behavior of 3D printed acrylonitrile butadiene styrene (ABS)/carbon black electrodes was influenced by printing direction. The electrodes were printed in both horizontal and vertical directions. The horizsontal direction resulted in a smooth surface (HPSS electrode) and a comparatively rougher surface (HPRS electrode) surface. Electrodes were characterized using cyclic voltammetry, electrochemical impedance spectroscopy and chronoamperometry. For various redox couples, the vertical printed (VP) electrode showed enhanced current response when compared the two electrode surfaces generated by horizontal print direction. No differences in the capacitive response was observed, indicating that the conductive surface area of all types of electrodes were identical. The VP electrode had reduced charge transfer resistance and uncompensated solution resistance when compared to the HPSS and HPRS electrodes. Overall, electrodes printed in a vertical direction provide enhanced electrochemical performance and our study indicates that print orientation is a key factor that can be used to enhance sensor performance.