This study investigates the influence of synthesis methods and electrode geometry on the physico-chemical properties of 5%Gd-doped SnO2. Two distinct synthesis routes, co-precipitation and hydrothermal growth, were employed, resulting in powders denoted as SnO2: Gd 5%-CP and SnO2: Gd 5%-HT. Morpho-structural and textural analyses reveal a uniform morphology consisting of quasi-spherical nanoparticles with dimensions of ~6 nm and mesoporosity for CP and a non-uniform morphology with larger nanoparticles of ~42 nm, with irregular shapes and macroporosity for the HT sample, respectively. The powders were deposited onto alumina substrates equipped with platinum interdigital electrodes with alternative gaps of 200 μm and 100 μm. The back-side heater allows for variation in the temperature of the layer. Sensing properties assessed under in-field-like atmospheres simulated by a computer-controlled Gas Mixing System reveal higher sensitivity to methane compared to carbon dioxide. Although the sensor signals did not differ quantitatively, they exhibited distinct saturation tendencies with an increasing methane concentration, attributed to the morpho-structure and porosity induced by the synthesis method. Differentiation was achieved by varying the interdigital gap of the electrodes, highlighting different sensor signals and conduction mechanisms, determined by the specific size of the crystallites.
