3D Printed Smart Polymeric Sensors for Real-Time Detection of Toxic Gases and Thermo-Mechanical Stress in Hazardous Environments

Context

Many high-risk environments, such as fires, industrial sites, or confined spaces, expose workers to extreme conditions combining invisible toxic gases (volatile organic compounds, CO, HCN, solvents and fumes), high temperatures, and significant mechanical stress associated with equipment and movement. Early detection of these hazards is a major health and safety challenge. However, there are currently no flexible sensors that can be integrated into garments or structures and capable of simultaneously monitoring chemical exposure, mechanical strain, and thermal conditions in real time.

Recent advances in additive manufacturing, functional polymer materials, and nanomaterials now offer a unique opportunity to develop smart, flexible sensors that can be integrated into technical textiles or lightweight structures. In particular, the use of piezoelectric polymers, conductive elastomers, and active fillers such as Metal–Organic Frameworks (MOFs) enables the design of multifunctional sensing systems capable of responding simultaneously to chemical and mechanical stimuli.

PhD Objectives

This project aims to develop a new generation of 3D printed smart sensors that can be integrated into technical textiles or structural components and are capable of real-time detection of toxic gases, mechanical deformation, and thermal variations, in order to improve personal safety and monitoring in hazardous environments.

Research Plan

The PhD candidate will:

1. Develop printable polymer formulations suitable for additive manufacturing

2. Incorporate functional fillers (MOFs, conductive nanoparticles) into polymer matrices

3. Design multi-material printed architectures with localized sensing zones

4. Optimize 3D printing processes (DIW, extrusion) and morphology control

5. Investigate electro-mechanical, piezoresistive, and piezoelectric properties of the sensors

6. Evaluate detection of toxic gases (VOCs, CO, solvents, fumes)

7. Integrate the sensors into technical textiles or lightweight structures and validate durability and performance under realistic conditions

Research Environment

During this PhD, the student will develop advanced expertise in additive manufacturing, functional polymer materials, and smart sensing systems. The candidate will acquire highly valuable skills in printable ink formulation, polymer–MOF nanocomposites, electro-mechanical characterization, and integrated device design. The project also offers training in innovation and technology transfer, including opportunities to collaborate with industrial partners, contribute to patent applications, and publish in high-impact scientific journals.

The PhD candidate will join the Canada Research Chair in Polymer Rheology, an internationally recognized research environment known for excellence in advanced rheology, functional polymeric materials, additive manufacturing, and the development of membranes and intelligent systems, as well as nanocomposites and MOFs. The Chair benefits from state-of-the-art infrastructure including advanced rheometry, polymer processing and 3D printing platforms, and comprehensive characterization tools. It maintains strong industrial collaborations in energy, transportation, and advanced materials, as well as international academic partnerships across Europe, the Americas, and Asia. The supervision is multidisciplinary and provides a stimulating environment at the interface of materials science, additive manufacturing, and sensor engineering.

Expected Impact

This project will contribute to the development of lightweight, flexible, and integrable sensing systems enabling early detection of toxic environments and improved monitoring of stresses experienced by equipment or structures. It has strong potential for innovation, industrial transfer, and commercialization, with direct impact on worker safety and protection in hazardous environments. The technological platform developed may also be extended to other applications such as smart medical textiles, aerospace structural monitoring, and environmental sensing.