A cost-effective, scalable and versatile method of preparing nano-ink without hazardous chemical precursors is a prerequisite for widespread adoption of printed electronics. Precursor-free synthesis by spark discharge is promising for this purpose. The synthesis of platinum nanoparticles (PtNPs) using a spark discharge under Ar, N₂, and air has been investigated to prepare highly conductive nano-ink. The size, chemical composition, and mass production rate of PtNPs significantly depended on the carrier gas. Pure metallic PtNPs with sizes of 5.5 ± 1.8 and 7.1 ± 2.4 nm were formed under Ar and N₂, respectively. PtNPs with sizes of 18.2 ± 9.0 nm produced using air consisted of amorphous oxide PtO and metallic Pt. The mass production rates of PtNPs were 53 ± 6, 366 ± 59, and 490 ± 36 mg/h using a spark discharge under Ar, N₂, and air, respectively. It was found that the energy dissipated in the spark gap is not a significant parameter that determines the mass production rate. Stable Pt nano-ink (25 wt.%) was prepared only on the basis of PtNPs synthesized under air. Narrow (about 30 μm) and conductive Pt lines were formed by the aerosol jet printing with prepared nano-ink. The resistivity of the Pt lines sintered at 750 °C was (1.2 ± 0.1)·10⁻⁷ Ω·m, which is about 1.1 times higher than that of bulk Pt.

Germanium–tin nanoparticles are promising materials for near- and mid-infrared photonics thanks to their tunable optical properties and compatibility with silicon technology. This work proposes modifying the spark discharge method to produce Ge/Sn aerosol nanoparticles during the simultaneous erosion of germanium and tin electrodes. Since tin and germanium have a significant difference in the potential for electrical erosion, an electrical circuit damped for one period was developed to ensure the synthesis of Ge/Sn nanoparticles consisting of independent germanium and tin crystals of different sizes, with the ratio of the atomic fraction of tin to germanium varying from 0.08 ± 0.03 to 0.24 ± 0.07. We investigated the elemental and phase composition, size, morphology, and Raman and absorbance spectra of the nanoparticles synthesized under different inter-electrode gap voltages and the presence of additional thermal treatment directly in a gas flow at 750 °C. The research shows that the in-flow thermal treatment of aerosol-agglomerated nanoparticles produced special individual bicrystalline Janus Ge/Sn nanoparticles with an average size of 27 nm and a decreasing absorption function with a changing slope at 700 nm.

An analyzed substance’s signal intensity and detection sensitivity in surface-enhanced Raman spectroscopy (SERS) significantly depend on the size and agglomeration degree of nanoparticles (NPs) forming the enhancing structure. Structures were manufactured by aerosol dry printing (ADP), where NPs’ agglomeration depends on printing conditions and additional particle modification techniques. The influence of agglomeration degree on SERS signal enhancement was studied in three types of printed structures using the methylene blue model molecule as an analyte. We demonstrated that the ratio between individual NPs and agglomerates in a studied structure strongly affects SERS signal amplification, and structures formed mainly from non-agglomerated NPs enhance the signal better. In this sense, aerosol NPs modified by pulsed laser radiation provide better results than thermally modified NPs, since in laser modification a larger number of individual NPs is observed due to the absence of secondary agglomeration effects in the gas stream. However, increasing gas flow may minimize the secondary agglomeration, since the time allotted for the agglomeration processes is reduced. In this paper, we show how different NPs’ agglomeration tendencies influence SERS enhancement to demonstrate the process of using ADP to form inexpensive and highly efficient SERS substrates with huge application potential.