Fabrication of Highly Sensitive Conformal Temperature Sensors on Stainless Steel via Aerosol Jet Printing

Promoting the development of aerospace vehicles toward structural–functional integration and intelligent sensing is a key strategy for achieving lightweight, high-reliability, and autonomous operation and maintenance of next-generation aircraft. However, traditional external sensors face significant limitations because of their bulky size, installation challenges, and incompatibility with aerodynamic surfaces. These issues are particularly pronounced on complex, high-curvature substrates, where achieving conformal bonding is difficult, thus restricting their application in critical components. In this study, aerosol jet printing (AJP) was employed to directly fabricate silver nanoparticle-based temperature sensors with real-time monitoring capabilities on the surface of high-curvature stainless steel sleeves, which serve as typical engineering components. This approach enables the in situ manufacturing of high-precision conformal sensors. Through optimized structural design and thermal treatment, the sensors exhibit reliable temperature sensitivity. Microscopic characterization reveals that the printed sensors possess uniform linewidths and well-defined outlines. After gradient sintering at 250 °C, a dense and continuous conductive path is formed, ensuring strong adhesion to the substrate. Temperature-monitoring results indicate that the sensor exhibits a nearly linear resistance response (R2> 0.999) across a broad detection range of 20–200 °C. It also demonstrates high sensitivity, characterized by a temperature coefficient of resistance (TCR) of 2.15 × 10−3/°Cat 20 °C. In repeated thermal cycling tests, the sensor demonstrates excellent repeatability and stability over 100 cycles, with resistance fluctuations kept within 0.5% and negligible hysteresis observed. These findings confirm the feasibility of using AJP technology to fabricate high-performance conformal sensors on complex surfaces, offering a promising strategy for the development of intelligent structural components in next-generation aerospace engineering.