Advancing Conductive Ink Formulations for DIW with Graphene and Hybrid Nanostructures

Year : 2025 | Volume : 12 | Issue : 03 | Page : 36 49
    By

    Jhunjhun Kumar Mishra,

  • Vishal Francis,

  1. Research Scholar, School of Mech Engineering, Lovely Professional University, Punjab, India
  2. Assistant Professor, School of Mech Engineering, Lovely Professional University, Punjab, India

Abstract

The development of solvent-based conductive inks for direct ink writing (DIW) has gained significant attention as a pathway toward flexible, wearable, and scalable electronic devices. This review critically examines conductive fillers, binders, solvent systems, and hybrid ink strategies reported in recent literature. Graphene and carbon nanotubes (CNTs) remain the most studied fillers due to their high intrinsic conductivity and unique dimensionality, but challenges such as restacking, bundling, and high viscosity necessitate dispersion control and optimized formulations. Binder materials play a decisive role in balancing dispersion stability with electrical performance: polyvinylpyrrolidone (PVP) consistently demonstrates superior stabilization at low concentrations compared to insulating binders such as polyvinyl alcohol (PVA) or brittle systems such as sodium silicate. Similarly, solvent selection is critical for DIW compatibility; ethanol-based systems require modification with ethylene glycol (EG) or terpineol to mitigate aggregation, suppress coffee-ring effects, and ensure rheological suitability. A key advancement highlighted in this review is the adoption of hybrid fillers, particularly graphene-CNT and graphene-Ag systems, which leverage synergistic conduction pathways to achieve conductivities in the range of 10³–10⁴ S/cm while maintaining flexibility. Literature consistently confirms that hybrid conductive inks, when stabilized with ≤3 wt% PVP in ethanol-EG or ethanol-terpineol blends, outperform single-filler systems in both conductivity and mechanical durability. Overall, hybrid architecture emerge as the most promising route for DIW-enabled printed electronics, providing a balance of printability, stability, and high electrical performance suitable for next-generation applications.

Keywords: Graphene-CNT hybrid networks, solvent-based conductive inks, DIW, conductive Ink printability, dispersion stability optimization

[This article belongs to Journal of Thin Films, Coating Science Technology & Application ]

How to cite this article:
Jhunjhun Kumar Mishra, Vishal Francis. Advancing Conductive Ink Formulations for DIW with Graphene and Hybrid Nanostructures. Journal of Thin Films, Coating Science Technology & Application. 2025; 12(03):36-49.
How to cite this URL:
Jhunjhun Kumar Mishra, Vishal Francis. Advancing Conductive Ink Formulations for DIW with Graphene and Hybrid Nanostructures. Journal of Thin Films, Coating Science Technology & Application. 2025; 12(03):36-49. Available from: https://journals.stmjournals.com/jotcsta/article=2025/view=233280


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Regular Issue Subscription Review Article
Volume 12
Issue 03
Received 17/10/2025
Accepted 24/10/2025
Published 15/11/2025
Publication Time 29 Days
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