Ultra-high response ethanol sensors from fully-printed co-continuous and mesoporous tin oxide thin films

•Co-continuous mesoporous SnO2 thin films have been inkjet-printed mimicking the evaporation induced self-assembly process.•Pore size and volume is found tunable when swelling agent ‘xylene’ is used alongside soft-templating agent pluronic F127.•The fully-printed high surface-to-volume ratio SnO2 sensor show high sensitivity of 1050 towards 100 ppm of ethanol.•High throughput printing techniques opens the possibilities of these sensors in pharmaceutical and food safety industries.