You can make fairly small batches, but it is dependent on how accurately you can measure ingredients. Another alternative is to make a 3% (maximum) stock solution of DAS. Measuring out small quantities of liquid is easier than small quantities of powder, IMO.
A single 4x5 inch tissue would only require about 10-15 ml of gelatin solution, so maybe only 1-1.5 grams of dry gelatin. And maybe only 60 milligrams of DAS. 2 ml of a 3% solution of DAS is 60 milligrams of DAS. Think carefully about exactly how small of batches you need.
Another possibility is to not make sensitizer-incorporated tissue. Rather, make a traditional carbon tissue, and tray- or brush-sensitize the DAS onto the tissue, replicating the process one would use for dichromates. This way tests and samples of tissue that are no longer useful to you can be discarded with little cost (pigment and gelatin cost relatively little compared to DAS.) Just something to think about. If you've never carbon printed before, it will take a few tries to get a recipe nailed down.
Yet another alternative would be to use pre-made tissues (Bostick & Sullivan). Then you can get used to working with the DAS by tray- or brush-sensitizing without the additional complications of making tissue.
Lastly, DAS is very highly unlikely to work with traditional carbro recipes. Carbro relies on a completely different chemical reaction to harden gelatin than traditional carbon printing. In order to develop a carbro-like process with DAS, you would need find a chemical (or chemicals) that will react in proportion to the amount of silver in your bromide printer to break the azide groups in the DAS which would cause imagewise hardening of the gelatin. Certainly not impossible if you're skilled in chemistry. But it is extremely unlikely that the traditional carbro recipes will work.
Best of luck...
Hey Greg, in your testing did you use water or alcohol as your solvent for the 3% solution? In reading the threads it seems both are viable?
From someone that's used to working with Potassium Dichromate w/ acetone, is spirit sensitizing with DAS similar?