Life-Cycle Assessment of Humidity Sensors printed with Forest-based Ink and Laser Graphitization

Abstract: The increasing demand for digitalization has spurred the need for novel and sustainable designs of electronic devices like sensors. Advanced additive print technologies, organic inks, and bio-based substrates in device fabrication exhibit promising potential for reducing energy and raw material consumption, thereby alleviating environmental impacts. One such innovation is the novel method of laser graphitization in designing devices like printed humidity sensors. This study focuses on evaluating the environmental impacts of implementing this novel technique in the field of printed electronics. In particular, the thesis conducts a cradle-to-gate life cycle assessment (LCA) of producing a resistive-type humidity sensor from a forest-based wood ink using laser graphitization. The sensor is based on the design that was demonstrated in the lab facilities at the Research Institutes of Sweden (RISE), Norrköping. The assessment is at a lab-scale production of making 1mm2 area of a laser-induced graphitized (LIG) sensor, excluding usage, disposal, or recycling phases. The results highlight impacts from electricity usage as the primary contributor to the overall environmental impacts, across the production process, followed by the impacts from material usage. The impact share distribution from these two hotspots identifies opportunities in the process that need to be prioritized for immediate actions. Sensitivity analyses varying the sensor layer thickness and the electricity mix of the laboratory facilities reveal insightful impact trends. The results from scenario analyses show the LIG sensor to have much lower environmental impacts than that of a sensor with silver electrodes and carbon-based sensing ink. They also show potential for achieving economies of scale from the mass production of LIG sensors. The data inventory for the processes and components of the sensor stands as a crucial part of this study, relying heavily on literature, assumptions, and proxy data. While these may reveal some uncertainties and limitations, the study nonetheless, serves as an important reference for future research concerning similar databases and a cradle-to-grave LCA of the sensor.