This cumulative thesis addresses the environmental burden associated with single-use and disposable sensors, particularly in point-of-care and smart packaging applications. It presents the development of a sustainable wireless sensor system that integrates experimental sensor development with environmental assessment. The result is a comprehensive approach combining sustainable material deployment, sensor system design, and Life Cycle Assessment (LCA) - addressing sustainability from component to system level. Particular focus is placed on the systematic investigation of the sensing behavior of chitosan films under controlled exposure to water vapor and VOCs. The results show that chitosan ex-hibits a dominant response to humidity compared to its response to VOCs. This work presents the first fully additively manufactured chitosan-based humidity sensor, demonstrates direct laser carbonization of chitosan films, and identifies proton hopping as the dominant, oxygen-independent conduction mechanism. While VOC selectivity was shown to be limited, the findings enable a critical reflection on chitosan's real-world limitations in printed electronics, including encapsulation and substrate compatibility. Building on this, a printed hybrid near-field communication (NFC)-based sensor tag was developed for wireless monitoring of acetone vapor and humidity. The system comprises a chitosan-based resistive sensor, a printed antenna, and a commercial NFC chip, all integrated onto a single bio-based substrate. The system features a room-temperature flip-chip bonding process and demonstrates a feasible manufacturing pathway for hybrid sensor tags on thermally sensitive substrates. The compact, energy-autonomous design has practical potential for point-of-care diagnostics and smart packaging applications. To critically assess the environmental impacts of such systems, a full LCA with the focus on carbon footprinting was conducted for representative printed and hybrid sensor configurations. Contrary to expectations, despite being the dominant mass fraction, the substrate showed relatively low environmental impact, whereas the sensor chip and silver nanoparticle-based inks were identified as major environmental hotspots. Furthermore, challenges related to end-of-life treatment and the lack of recycling infrastructure for hybrid systems were highlighted. The study emphasizes the importance of early-stage sustainability considerations in printed sensor design and provides guidance for informed material and process selection. By combining experimental, system-level, and environmental perspectives, this work contributes to the advancement of sustainable printed electronics and identifies key challenges and opportunities for future development.
EPFL
Prof. Mahsa Shoaran (présidente) ; Prof. Sandro Carrara, Dr Jürgen Kosel (directeurs) ; Prof. Danick Briand, Prof. Matti Mäntysalo, Prof. Wim Deferme (rapporteurs)
2025
Lausanne
2025-10-31
11704
124