Systems and methods for a printed electrochemical gas sensor

A method of manufacturing an electrochemical sensor, the method comprising:

• providing a plurality of electrodes over a substrate comprising diffusion holes, the plurality of electrodes covering the diffusion holes extending cylindrically through the thickness of the substrate;
• applying a transition layer comprising at least a first mixture of a water immiscible liquid and a hydrophilic inert substance over the plurality of electrodes;
• and
• applying an electrolyte layer comprising at least a second mixture of an acid solution and a solid polymer over the transition layer.

A method of manufacturing an electrochemical sensor, the method comprising:

• printing, in a vacuum, a slurry over a substrate to form a plurality of electrodes on the substrate, wherein the plurality of electrodes cover one or more diffusion holes through the substrate;
• printing a transition layer comprising a mixture of a water immiscible liquid and a hydrophilic inert substance over the plurality of electrodes;
• and
• providing an electrolyte layer comprising at least a second mixture of an acid solution and a solid polymer over the transition layer, wherein the electrolyte layer provides electrical contact between the plurality of electrodes.