Optimizing Carbon Structures in Laser-Induced Graphene Electrodes Using Design of Experiments for Enhanced Electrochemical Sensing Characteristics

In this study, we explored the morphological and electrochemical properties of carbon-based electrodes derived from laser-induced graphene (LIG) and compared them to commercially available graphene-sheet screen-printed electrodes (GS-SPEs). By optimizing the laser parameters (average laser power, speed, and focus) using a design of experiments response surface (DoE-RS) approach, binder-free LIG electrodes were achieved in a single-step process. Traditional trial-and-error methods can be time-consuming and may not capture the interactions between all variables effectively. To address this, we focused on linear resistance and substrate delamination to streamline the DoE-RS optimization process. Two LIGs, designated LIG A and LIG B, were fabricated using distinct and optimized laser settings, which resulted in a sheet resistance of 25 +/- 2 Omega/sq and 21 +/- 1 Omega/sq, respectively. These LIGs, characterized by scanning electron microscopy, Raman spectroscopy, and contact angle analysis, exhibited a highly porous morphology with 13% pore coverage and a contact angle <50 degrees, which significantly increased their hydrophilicity when compared to the GS-SPE. For the electrochemical studies, the oxidation of NO2- ion by the graphene-based working electrodes was investigated, as it allowed for the direct comparison of the LIGs to the GS-SPE. These included cyclic voltammetry, electrochemical impedance spectroscopy, and differential pulsed voltammetry studies, which revealed that LIG electrodes displayed a remarkable 500% increase in peak current during NO2- oxidation compared to the GS-SPE. The LIGs also demonstrated improved stability and sensitivity (420 +/- 30 and 570 +/- 10 nA mu M-1 cm(-2)) compared to the GS-SPE (73 +/- 4 nA mu M-1 cm(-2)) in the oxidation of NO2- ions; however, LIG B was more susceptible to ionic interference than LIG A. These findings highlight the value of applying statistical approaches such as DoE-RS to systematically improve the LIG fabrication process, enabling the rapid production of optimized LIGs that outperform conventional carbon-based electrodes.