Rapid Room-Temperature Synthesis of ZnO Nanoparticles with Styrene Gas Detection for Flexible Sensors

Efficient synthesis routes for zinc oxide nanoparticles (ZnO NPs) that are rapid and non-toxic and operate at room temperature (RT) are essential to expand accessibility, minimize environmental impact, and enable integration with temperature-sensitive substrates. In this work, ZnO NPs were synthesized by probe ultrasonication at RT for durations from 30 s to 10 min and benchmarked against our previously reported water bath sonication method. A 10-min probe treatment yielded highly uniform ZnO NPs with particle sizes of 60–550 nm and a specific surface area of up to 75 m² g⁻¹, compared to ~38 m² g⁻¹ for bath sonication. These features were largely preserved after calcination at 500 °C. When integrated into chemiresistive devices, the resulting ZnO (P(10))-based sensors exhibited pronounced selectivity toward styrene, showing reversible responses at low concentrations (10–50 ppm) and stronger signals at higher levels (up to 200 ppm, with resistance changes reaching 2930%). The sensors demonstrated stable operation across 10–90% relative humidity, and consistent performance from −20 °C to 180 °C. Flexibility tests confirmed reliable sensing after 100 bending cycles at 30°. Overall, RT-probe ultrasonication offers a rapid, scalable, and eco-friendly route to ZnO NPs with tunable properties, opening new opportunities for flexible gas sensing.