Single-step fabrication of an integrated 3D-printed device for electrochemical sensing applications

Merging 3D-printing technology and disposable materials for electrochemical purposes: A sustainable alternative to ensure greener electroanalysis

3D-printing technology has revolutionized electrochemical applications by enabling rapid prototyping of various devices with high precision, even in highly complex structures. However, a significant challenge remains in developing less costly and more sustainable analytical approaches and methods aimed at mitigating the negative environmental impacts of chemical analysis procedures. In this study, we propose a solution to these challenges by creating a simple and versatile electrochemical system that combines 3D-printing technology with recyclable disposable materials, such as graphite from an exhausted battery and a stainless-steel screw. Our results demonstrate a novel strategy for developing electrodes and other laboratory-made devices that align with the principles of sustainability and green chemistry. Furthermore, we provide evidence of the effectiveness of the proposed system in an analytical application involving the simultaneous determination of tert-butylhydroquinone, acetaminophen, and levofloxacin using the voltammetric technique in lake and groundwater samples. The results indicate sufficient accuracy, with recovery values ranging from 91 to 110%. Additionally, we utilized the Analytical GREEnness calculator as a metric system to evaluate the environmental friendliness of the proposed electroanalytical protocol. The final score confirms a favorable level of sustainability, reaffirming the eco-friendly nature of our approach.

Electroanalysis overview: additive manufactured biosensors using fused filament fabrication

Additive manufacturing (3D-printing), in particular fused filament fabrication, presents a potential paradigm shift in the way electrochemical based biosensing platforms are produced, giving rise to a new generation of personalized and on-demand biosensors. The use of additive manufactured biosensors is unparalleled giving rise to unique customization, facile miniaturization, ease of use, economical but yet, still providing sensitive and selective approaches towards the target analyte. In this mini review, we focus on the use of fused filament fabrication additive manufacturing technology alongside different biosensing approaches that exclusively use antibodies, enzymes and associated biosensing materials (mediators) providing an up-to-date overview with future considerations to expand the additive manufacturing biosensors field.

Print-Pause-Print Fabrication of Tailored Electrochemical Microfluidic Devices

Three-dimensional (3D) printing technology has emerged as a powerful technology for the fabrication of low-cost microfluidics. Nevertheless, the fabrication of microfluidic devices integrating high-performance electrochemical sensors in practical applications is still an open challenge. Although automatic fabrication of the microfluidic device and the electrodes can be successfully carried out using a one-step multimaterial fused filament fabrication (FFF) approach, the as-printed electrochemical performance of these electrodes is not good enough for chemical (bio)sensing and their surface modification is challenging because after closing the channel there is no physical access to the electrode. Thus, here a pause-print-pause (PPP) microfabrication approach was implemented. The fabrication was paused before printing the microfluidics, and the filament-based electrodes were directly modified on the printing bed via stencil printing, drop casting, and electrodeposition. To exemplify this versatile workflow, the design of a microfluidic glucose sensor was proposed. To this end, first, the working and counter electrodes were stencil printed with graphite ink while the reference electrode was stencil printed with Ag|AgCl ink. Then, Prussian blue was formed on the working electrode either by drop casting or by electrodeposition, and glucose oxidase was drop cast on top. At this point, the microfabrication process was resumed, and the microfluidics were printed on top of the modified electrodes to complete the construction of hybrid electrochemical fluidic fused filament fabricated devices (h-eF4Ds). This print-pause-print approach is not limited to ink-based electrodes or glucose oxidase, and we envisage these results will pave the way for the effective integration of electrodes in microfluidic devices in a simple and clean-room-free approach, allowing the development of highly customized eF4Ds for a plethora of analytes with high significance.

Fabrication and integration of a low-cost 3D printing-based glucose biosensor for bioprinted liver-on-a-chip

In the last two decades, significant progress has been made in the development of more physiologically relevant organ-on-a-chip (OOC) systems that can mimic tissue microenvironments. Despite the advantages of these microphysiological systems, such as portability, ability to mimic physiological flow conditions, and reduction of the number of reagents required for preparation and detection, they lack real-time analyte detection with high accuracy. To address this limitation, biosensor technologies have been integrated with OOC systems to facilitate simultaneous analysis of different analytes with a single device. However, the integration of biosensors with OOC systems is challenging because of the competing demands of low-cost, simple fabrication processes and speed. In this study, we fabricate a glucose-sensing device and integrate it with a liver-on-a-chip (LOC) platform. A carbon black-polylactic acid-based three-electrode system was printed using fused deposit molding 3D printing technology to simplify the fabrication process. The sensitivity of the fabricated glucose biosensing device was enhanced by coating the electrodes with multi-walled carbon nanotubes. A biosensing integration study performed using a perfusion-based LOC demonstrated the stability, biocompatibility, and sensitivity of the proposed glucose sensing device. Furthermore, drug-toxicity studies conducted using the LOC platform demonstrated the ability of the device to detect a broad range of glucose concentrations and its enhanced sensitivity.

Electrochemical platform produced by 3D printing for analysis of small volumes using different electrode materials

Fused deposition modeling (FDM) 3D printing is a promising additive manufacturing technique to produce low-cost disposable electrochemical devices. However, the print of devices like well-known screen-printed electrodes (all electrodes on the same device) is difficult using the available technology (few materials available for production of working electrodes). In this paper we present a procedure to produce disposable and robust electrochemical devices by FDM 3D printing that allows reproducible analysis of small volumes (50-2000 μL). The device consists of just two printed parts that allow easy coupling of different conductive materials for using as disposable or non-disposable working electrodes with reproducible geometric area. Printed counter and pseudo-reference electrodes can also be easily fitted into the microcell. Moreover, conventional counter (platinum wire) and mini reference electrodes can also be used. As a proof of concept, paracetamol, cocaine and uric acid were used as model analytes using different materials as working electrodes. Linear calibration curves (r > 0.99) with similar slopes (0.29 ± 0.01 μA μmol L-1; RSD = 3.4%) were obtained by square wave voltammetry (SWV) using a complete printed system and different volumes of standard solutions of paracetamol (50, 100, and 200 μL). For uric acid, a linear range of 10-125 μmol L-1 (r > 0.99), was obtained using differential pulse voltammetry as the electrochemical technique and a disposable laser-induced graphene base as the working electrode. With the coupling of boron-doped diamond working electrode, screening tests were successfully performed in seized cocaine samples with selective detection of cocaine in the presence of its most common adulterants. The production cost per unit of a complete electrochemical system is around US 5.00. In large-scale production, only the working electrode needs to be replaced while the microcell and counter/pseudo reference electrodes do not need to be discarded.

Novel Additive Manufactured Multielectrode Electrochemical Cell with Honeycomb Inspired Design for the Detection of Methyl Parathion in Honey Samples

The development and increase in the number of crops recently have led to the requirement for greater efficiency in world food production and greater consumption of pesticides. In this context, the widespread use of pesticides has affected the decrease in the population of pollinating insects and has caused food contamination. Therefore, simple, low-cost, and quick analytical methods can be interesting alternatives for checking the quality of foods such as honey. In this work, we propose a new additively manufactured (3D-printed) device inspired by a honeycomb cell, with 6 working electrodes for the direct electrochemical analysis of methyl parathion by reduction process monitoring in food and environmental samples. Under optimized parameters, the proposed sensor presented a linear range between 0.85 and 19.6 μmol L^-1, with a limit of detection of 0.20 μmol L^-1. The sensors were successfully applied in honey and tap water samples by using the standard addition method. The proposed honeycomb cell made of polylactic acid and commercial conductive filament is easy to construct, and there is no need for chemical treatments to be used. These devices based on 6 working electrodes array are versatile platforms for rapid, highly repeatable analysis in food and environment, capable of performing detection in low concentrations.

3D printing for customized carbon electrodes

Traditional carbon electrodes are made of glassy carbon or carbon fibers and have limited shapes. 3D printing offers many advantages for manufacturing carbon electrodes, such as complete customization of the shape and the ability to fabricate devices and electrodes simultaneously. Additive manufacturing is the most common 3D printing method, where carbon materials are added to the material to make it conductive, and treatments applied to enhance electrochemical activity. A newer form of 3D printing is 2-photon lithography, where electrodes are printed in photoresist via laser lithography and then annealed to carbon by pyrolysis. Applications of 3D printed carbon electrodes include nanoelectrode measurements of neurotransmitters, arrays of biosensors, and integrated electrodes in microfluidic devices.

Influence of instrument parameters on the electrochemical activity of 3D printed carbon thermoplastic electrodes

3D printing provides a reliable approach for the manufacture of carbon thermoplastic composite electrochemical sensors. Many studies have explored the impact of printing parameters on the electrochemical activity of carbon thermoplastic electrodes but limited is known about the influence of instrument parameters, which have been shown to alter the structure and mechanical strength of 3D printed thermoplastics. We explored the impact of extruder temperature, nozzle diameter and heated bed temperature on the electrochemical activity of carbon black/poly-lactic acid (CB/PLA) electrodes. Cyclic voltammetry and electrochemical impedance spectroscopy measurements were conducted using standard redox probes. The electrode surface and cross-section of the electrode was visualised using scanning electron microscopy. We found that using extruder temperatures of 230 °C and 240 °C improved the electrochemical activity of CB/PLA electrodes, due to an increase in surface roughness and a reduction in the number of voids in-between print layers. Nozzle diameter, heated bed temperature of different 3D printers did not impact the electrochemical activity of CB/PLA electrodes. However high-end printers provide improved batch reproducibility of electrodes. These findings highlight the key instrument parameters that need to be considered when manufacturing carbon thermoplastic composite electrochemical sensors when using 3D printing.

Adjusting the Connection Length of Additively Manufactured Electrodes Changes the Electrochemical and Electroanalytical Performance

Changing the connection length of an additively manufactured electrode (AME) has a significant impact on the electrochemical and electroanalytical response of the system. In the literature, many electrochemical platforms have been produced using additive manufacturing with great variations in how the AME itself is described. It is seen that when measuring the near-ideal outer-sphere redox probe hexaamineruthenium (III) chloride (RuHex), decreasing the AME connection length enhances the heterogeneous electrochemical transfer (HET) rate constant (k0) for the system. At slow scan rates, there is a clear change in the peak-to-peak separation (ΔEp) observed in the RuHex voltammograms, with the ΔEp shifting from 118 ± 5 mV to 291 ± 27 mV for the 10 and 100 mm electrodes, respectively. For the electroanalytical determination of dopamine, no significant difference is noticed at low concentrations between 10- and 100-mm connection length AMEs. However, at concentrations of 1 mM dopamine, the peak oxidation is shifted to significantly higher potentials as the AME connection length is increased, with a shift of 150 mV measured. It is recommended that in future work, all AME dimensions, not just the working electrode head size, is reported along with the resistance measured through electrochemical impedance spectroscopy to allow for appropriate comparisons with other reports in the literature. To produce the best additively manufactured electrochemical systems in the future, researchers should endeavor to use the shortest AME connection lengths that are viable for their designs.

Three-Dimensional Printing and Its Potential to Develop Sensors for Cancer with Improved Performance

Cancer is the second leading cause of death globally and early diagnosis is the best strategy to reduce mortality risk. Biosensors to detect cancer biomarkers are based on various principles of detection, including electrochemical, optical, electrical, and mechanical measurements. Despite the advances in the identification of biomarkers and the conventional 2D manufacturing processes, detection methods for cancers still require improvements in terms of selectivity and sensitivity, especially for point-of-care diagnosis. Three-dimensional printing may offer the features to produce complex geometries in the design of high-precision, low-cost sensors. Three-dimensional printing, also known as additive manufacturing, allows for the production of sensitive, user-friendly, and semi-automated sensors, whose composition, geometry, and functionality can be controlled. This paper reviews the recent use of 3D printing in biosensors for cancer diagnosis, highlighting the main advantages and advances achieved with this technology. Additionally, the challenges in 3D printing technology for the mass production of high-performance biosensors for cancer diagnosis are addressed.

Additively manufactured electrodes for the electrochemical detection of hydroxychloroquine

Although studies have demonstrated the inactivity of hydroxychloroquine (HCQ) towards SARS-CoV-2, this compound was one of the most prescribed by medical organizations for the treatment of hospitalized patients during the coronavirus pandemic. As a result of it, HCQ has been considered as a potential emerging contaminant in aquatic environments. In this context, we propose a complete electrochemical device comprising cell and working electrode fabricated by the additive manufacture (3D-printing) technology for HCQ monitoring. For this, a 3D-printed working electrode made of a conductive PLA containing carbon black assembled in a 3D-printed cell was associated with square wave voltammetry (SWV) for the fast and sensitive determination of HCQ. After a simple surface activation procedure, the proposed 3D-printed sensor showed a linear response towards HCQ detection (0.4-7.5 μmol L^-1) with a limit of detection of 0.04 μmol L^-1 and precision of 2.4% (n = 10). The applicability of this device was shown to the analysis of pharmaceutical and water samples. Recovery values between 99 and 112% were achieved for tap water samples and, in addition, the obtained concentration values for pharmaceutical tablets agreed with the values obtained by spectrophotometry (UV region) at a 95% confidence level. The proposed device combined with portable instrumentation is promising for on-site HCQ detection.

Conductive printable electrodes tuned by boron-doped nanodiamond foil additives for nitroexplosive detection

An efficient additive manufacturing-based composite material fabrication for electrochemical applications is reported. The composite is composed of commercially available graphene-doped polylactide acid (G-PLA) 3D printouts and surface-functionalized with nanocrystalline boron-doped diamond foil (NDF) additives. The NDFs were synthesized on a tantalum substrate and transferred to the 3D-printout surface at 200 °C. No other electrode activation treatment was necessary. Different configurations of low- and heavy-boron doping NDFs were evaluated. The electrode kinetics was analyzed using electrochemical procedures: cyclic voltammetry and electrochemical impedance spectroscopy. The quasi-reversible electrochemical process was reported in each studied case. The studies allowed confirmation of the CV peak-to-peak separation of 63 mV and remarkably high heterogeneous electron transfer rate constant reaching 6.1 × 10⁻² cm s⁻¹ for 10 k ppm [B]/[C] thin NDF fitted topside at the G-PLA electrode. Differential pulse voltammetry was used for effective 2,4,6-trinitrotoluene (TNT) detection at the studied electrodes with a 87 ppb limit of detection, and wide linearity range between peak current density and the analyte concentration (0.064 to 64 ppm of TNT). The reported electrode kinetic differences originate primarily from the boron-dopant concentration in the diamond and the various contents of the non-diamond carbon phase.

Innovation in potentiometry: 3D-printed polylactic acid-based ion-selective bulk electrode membranes

Although ion-selective membrane-based potentiometric sensors have already proved their analytical performance in several fields of life, their applicability is still limited in practice. Biodegradable, ionic additive-free, polylactic acid-based bulk electrode membrane matrix containing various environmentally friendly polyethylene glycol derivatives as plasticizer was developed for the first time to replace the conventional PVC-based ones. Moreover, the first introduction of 3D printing in potentiometric chemosensing was also reported. It was demonstrated that a thoroughly optimized and generalizable procedure for filament extrusion combined with 3D printing technology provides a unique tool for series production of the redesigned ion-selective bulk electrochemical membranes. Finally, the potentiometric detection of Hg2+ in water was carried out as a proof-of-concept study on sensing. Results showed an unexpected improvement in electrochemical characteristics of the novel membranes compared to their conventional analogues. The present work expanded the practical applicability of conventional potentiometric cation-selective electrode membranes enabling their green, decentralized, and automated state-of-the-art manufacturing using a novel matrix composition.

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Electrochemical (Bio)Sensors Enabled by Fused Deposition Modeling-Based 3D Printing: A Guide to Selecting Designs, Printing Parameters, and Post-Treatment Protocols

The 3D printing (or additive manufacturing, AM) technology is capable to provide a quick and easy production of objects with freedom of design, reducing waste generation. Among the AM techniques, fused deposition modeling (FDM) has been highlighted due to its affordability, scalability, and possibility of processing an extensive range of materials (thermoplastics, composites, biobased materials, etc.). The possibility of obtaining electrochemical cells, arrays, pieces, and more recently, electrodes, exactly according to the demand, in varied shapes and sizes, and employing the desired materials has made from 3D printing technology an indispensable tool in electroanalysis. In this regard, the obtention of an FDM 3D printer has great advantages for electroanalytical laboratories, and its use is relatively simple. Some care has to be taken to aid the user to take advantage of the great potential of this technology, avoiding problems such as solution leakages, very common in 3D printed cells, providing well-sealed objects, with high quality. In this sense, herein, we present a complete protocol regarding the use of FDM 3D printers for the fabrication of complete electrochemical systems, including (bio)sensors, and how to improve the quality of the obtained systems. A guide from the initial printing stages, regarding the design and structure obtention, to the final application, including the improvement of obtained 3D printed electrodes for different purposes, is provided here. Thus, this protocol can provide great perspectives and alternatives for 3D printing in electroanalysis and aid the user to understand and solve several problems with the use of this technology in this field.

Recent Advances in 3D Printing of Biomedical Sensing Devices

Additive manufacturing, also called 3D printing, is a rapidly evolving technique that allows for the fabrication of functional materials with complex architectures, controlled microstructures, and material combinations. This capability has influenced the field of biomedical sensing devices by enabling the trends of device miniaturization, customization, and elasticity (i.e., having mechanical properties that match with the biological tissue). In this paper, the current state-of-the-art knowledge of biomedical sensors with the unique and unusual properties enabled by 3D printing is reviewed. The review encompasses clinically important areas involving the quantification of biomarkers (neurotransmitters, metabolites, and proteins), soft and implantable sensors, microfluidic biosensors, and wearable haptic sensors. In addition, the rapid sensing of pathogens and pathogen biomarkers enabled by 3D printing, an area of significant interest considering the recent worldwide pandemic caused by the novel coronavirus, is also discussed. It is also described how 3D printing enables critical sensor advantages including lower limit-of-detection, sensitivity, greater sensing range, and the ability for point-of-care diagnostics. Further, manufacturing itself benefits from 3D printing via rapid prototyping, improved resolution, and lower cost. This review provides researchers in academia and industry a comprehensive summary of the novel possibilities opened by the progress in 3D printing technology for a variety of biomedical applications.

Electrochemical Sensors for Antibiotic Susceptibility Testing: Strategies and Applications

Increasing awareness of the impacts of infectious diseases has driven the development of advanced techniques for detecting pathogens in clinical and environmental settings. However, this process is hindered by the complexity and variability inherent in antibiotic-resistant species. A great deal of effort has been put into the development of antibiotic-resistance/susceptibility testing (AST) sensors and systems to administer proper drugs for patient-tailored therapy. Electrochemical sensors have garnered increasing attention due to their powerful potential to allow rapid, sensitive, and real-time monitoring, alongside the low-cost production, feasibility of minimization, and easy integration with other techniques. This review focuses on the recent advances in electrochemical sensing strategies that have been used to determine the level of antibiotic resistance/susceptibility of pathogenic bacteria. The recent examples of the current electrochemical AST sensors discussed here are classified into four categories according to what is detected and quantitated: the presence of antibiotic-resistant genes, changes in impedance caused by cell lysis, current response caused by changes in cellular membrane properties, and changes in the redox state of redox molecules. It also discusses potential strategies for the development of electrochemical AST sensors, with the goal of broadening their practical applications across various scientific and technological fields.

New conductive filament ready-to-use for 3D-printing electrochemical (bio)sensors: Towards the detection of SARS-CoV-2

The 3D printing technology has gained ground due to its wide range of applicability. The development of new conductive filaments contributes significantly to the production of improved electrochemical devices. In this context, we report a simple method to producing an efficient conductive filament, containing graphite within the polymer matrix of PLA, and applied in conjunction with 3D printing technology to generate (bio)sensors without the need for surface activation. The proposed method for producing the conductive filament consists of four steps: (i) mixing graphite and PLA in a heated reflux system; (ii) recrystallization of the composite; (iii) drying and; (iv) extrusion. The produced filament was used for the manufacture of electrochemical 3D printed sensors. The filament and sensor were characterized by physicochemical techniques, such as SEM, TGA, Raman, FTIR as well as electrochemical techniques (EIS and CV). Finally, as a proof-of-concept, the fabricated 3D-printed sensor was applied for the determination of uric acid and dopamine in synthetic urine and used as a platform for the development of a biosensor for the detection of SARS-CoV-2. The developed sensors, without pre-treatment, provided linear ranges of 0.5-150.0 and 5.0-50.0 μmol L^-1, with low LOD values (0.07 and 0.11 μmol L^-1), for uric acid and dopamine, respectively. The developed biosensor successfully detected SARS-CoV-2 S protein, with a linear range from 5.0 to 75.0 nmol L^-1 (0.38 μg mL^-1 to 5.74 μg mL^-1) and LOD of 1.36 nmol L^-1 (0.10 μg mL^-1) and sensitivity of 0.17 μA nmol^-1 L (0.01 μA μg^-1 mL). Therefore, the lab-made produced and the ready-to-use conductive filament is promising and can become an alternative route for the production of different 3D electrochemical (bio)sensors and other types of conductive devices by 3D printing.

All-in-Fiber Electrochemical Sensing

Electrochemical sensors have found a wide range of applications in analytical chemistry thanks to the advent of high-throughput printing technologies. However, these techniques are usually limited to two-dimensional (2D) geometry with relatively large minimal feature sizes. Here, we report on the scalable fabrication of monolithically integrated electrochemical devices with novel and customizable fiber-based architectures. The multimaterial thermal drawing technique is employed to co-process polymer composites and metallic glass into uniform electroactive and pseudoreference electrodes embedded in an insulating polymer cladding fiber. To demonstrate the versatility of the process, we tailor the fiber microstructure to two configurations: a small-footprint fiber tip sensor and a high-surface-area capillary cell. We demonstrate the performance of our devices using cyclic voltammetry and chronoamperometry for the direct detection and quantification of paracetamol, a common anesthetic drug. Finally, we showcase a fully portable pipet-based analyzer using low-power electronics and an "electrochemical pipet tip" for direct sampling and analysis of microliter-range volumes. Our approach paves the way toward novel materials and architectures for efficient electrochemical sensing to be deployed in existing and novel personal care and surgical configurations.

Additive Manufacturing as a Means of Gas Sensor Development for Battery Health Monitoring

Lithium-ion batteries (LIBs) still need continuous safety monitoring based on their intrinsic properties, as well as due to the increase in their sizes and device requirements. The main causes of fires and explosions in LIBs are heat leakage and the presence of highly inflammable components. Therefore, it is necessary to improve the safety of the batteries by preventing the generation of these gases and/or their early detection with sensors. The improvement of such safety sensors requires new approaches in their manufacturing. There is a growing role for research of nanostructured sensor’s durability in the field of ionizing radiation that also can induce structural changes in the LIB’s component materials, thus contributing to the elucidation of fundamental physicochemical processes; catalytic reactions or inhibitions of the chemical reactions on which the work of the sensors is based. A current method widely used in various fields, Direct Ink Writing (DIW), has been used to manufacture heterostructures of Al2O3/CuO and CuO:Fe2O3, followed by an additional ALD and thermal annealing step. The detection properties of these 3D-DIW printed heterostructures showed responses to 1,3-dioxolan (DOL), 1,2-dimethoxyethane (DME) vapors, as well as to typically used LIB electrolytes containing LiTFSI and LiNO3 salts in a mixture of DOL:DME, as well also to LiPF6 salts in a mixture of ethylene carbonate (EC) and dimethyl carbonate (DMC) at operating temperatures of 200 °C–350 °C with relatively high responses. The combination of the possibility to detect electrolyte vapors used in LIBs and size control by the 3D-DIW printing method makes these heterostructures extremely attractive in controlling the safety of batteries.

Development of highly sensitive electrochemical sensor using new graphite/acrylonitrile butadiene styrene conductive composite and 3D printing-based alternative fabrication protocol

Here, a novel electrically conductive thermoplastic material composed of graphite/acrylonitrile butadiene styrene (G/ABS) is reported for the first time. This material was explored on the production of 3D printing-based electrochemical sensors with enhanced sensitivity using a novel fabrication approach. The developed G/ABS electrodes showed lower charge transfer resistance (157 vs. 3279 Ω), higher electroactive area (0.61 vs. 0.19 cm²) and peak currents ca. 69% higher when compared with electrodes fabricated using carbon black/polylactic acid (CB/PLA) commercial filament, which has been widely explored in recent literature. Moreover, the G/ABS sensor provided satisfactory repeatability, reproducibility and stability (relative standard deviations (RSDs) were 1.14%, 6.81% and 10.62%, respectively). This improved performance can be attributed to the fabrication protocol developed here, which allows the incorporation of greater amounts of conductive material in the polymeric matrix. The G/ABS electrode also required a simpler and quicker protocol for activation when compared to CB/PLA. As proof of concept, the G/ABS sensor was employed for electroanalytical quantification of paracetamol (PAR) in pharmaceutical products. The linear concentration range was observed from 0.20 to 30 μmol L^-1 and the limit of detection achieved was 54 nmol L^-1, much lower than several recent studies dealing with the same analyte. The sensitivity of the G/ABS electrode regarding PAR was also far better when compared to CB/PLA sensor (0.50 μA/μmol L^-1 vs. 0.12 μA/μmol L^-1). Analyses in commercial pill samples showed good accuracy (recoveries ca. 108%) and precision (RSDs < 5%), suggesting great potential for use of this novel conductive thermoplastic in electroanalytical applications based on 3D printing.

Highly Sensitive and Interference-Free Electrochemical Nitrite Detection in a 3D Printed Miniaturized Device

3D printing has a significant impact on various applications as it facilitates greater control over the designed shapes, leads to rapid prototyping and mass production with transferable designs at a lower cost. These attributes provide great versatility and thus make the devices industry-friendly. Herein, we demonstrate a simple and disposable 3D printed device, fabricated in single-step, as an electrochemical nitrite sensor using commercially available carbon loaded polylactic acid (PLA) filament. Nitrite, usually ingested through water and food, can be harmful when taken in excess. Thus, its efficient and accurate on-site detection becomes imperative. The device showed appreciable sensitivity and good selectivity towards nitrite having a limit-of-detection (LOD) of [Formula: see text]. Furthermore, the device has been shown to monitor nitrite in real soil and water samples with appreciable recovery values. Eventually, the device is capable to be multiplexed with varying soil parameters.

A novel all-3D-printed thread-based microfluidic device with an embedded electrochemical detector: first application in environmental analysis of nitrite

A microfluidic thread electroanalytical device (μTED) containing an embedded electrochemical detector is presented for the first time in this work. This novel device was entirely produced in an automated way using the fused deposition modeling (FDM) 3D printing technique. The main platform was fabricated with acrylonitrile butadiene styrene (ABS) filament, while the integrated electrochemical detector was produced using a commercial conductive filament composed of carbon black and polylactic acid (CB/PLA). The microfluidic channels consisted of cotton threads, which act as passive pumps, and the μTED was used for microflow injection analysis (μFIA). As a proof of concept, this μFIA system was utilized for the amperometric sensing of nitrite in natural waters. This is the first report on the use of both μTEDs and 3D-printed CB/PLA electrodes to determine this species. This fully 3D-printed μTED was characterized and all experimental and instrumental parameters related to the method were studied and optimized. Using the best conditions, the proposed approach showed a linear response in the concentration range from 8 to 200 μmol L^-1 and a limit of detection (LOD) of 2.39 μmol L^-1. The LOD obtained here was ca. ten-fold lower than the maximum contaminant level for nitrite in drinking water established by the Brazilian and US legislation. Moreover, the platform presented good repeatability and reproducibility (relative standard deviations (RSDs) were 2.1% and 2.5%, respectively). Lastly, the 3D-printed μTED was applied for the quantification of nitrite in well water samples and the results obtained showed good precision (RSD < 3%) and excellent concordance (relative error was ca.±3%) with those achieved by ion chromatography, used for validation.

Fully integrated 3D-printed electrochemical cell with a modified inkjet-printed Ag electrode for voltammetric nitrate analysis

To address the need for low-cost analytical tools for on-site aquaculture water quality monitoring, miniaturized electrochemical sensor systems can be readily fabricated using additive manufacturing technologies such as 3D printing and inkjet printing. In this work, we report the design and fabrication of an additively manufactured electrochemical platform featuring a reusable 3D-printed electrochemical cell with integrated reference and counter electrodes, and a replaceable inkjet-printed Ag (IJP-Ag) working electrode. The electrochemical cell was 3D-printed with acrylonitrile butadiene styrene (ABS) filament and features a 3D-printed ABS-carbon counter electrode and a Ag|AgCl|gel-KCl reference electrode with a 3D-printed porous junction directly integrated along the sides of the sample compartment. The application of the integrated cell is demonstrated with the analysis of nitrate ions on the IJP-Ag electrode, which was modified with electrodeposited nanostructured Ag to enhance sensitivity to nitrate reduction. Linear sweep voltammetry (LSV) was successfully applied to detect nitrate with a LOD of 1.40 ppm and a sensitivity of 0.2086 μA ppm^-1 in a background of artificial brackish aquaculture water (pH 8.0). The sensor response showed intra- and inter-electrode reproducibility and no significant interferences to most of the commonly encountered cations and anions in brackish water. The electrochemical sensor system was also applied to nitrate determination in real aquaculture water samples and demonstrated no significant differences with the results obtained using the standard spectrophotometric method at a 95% confidence level. Our results show how additive manufacturing is a promising approach to readily fabricate fit-for-purpose, low-cost miniaturized electrochemical sensor systems for point-of-use applications.

Smartphone-Addressable 3D-Printed Electrochemical Ring for Nonenzymatic Self-Monitoring of Glucose in Human Sweat

Nowadays, there is increased demand for wearable sensors for sweat glucose monitoring in order to facilitate diabetes management in a patient-friendly and noninvasive manner. This work describes a wearable glucose monitoring device in the form of an electrochemical ring (e-ring) fabricated by 3D printing. The 3D-printed e-ring consists of three carbon-based plastic electrodes (fabricated using a conductive filament) integrated at the inner side of a ring-shaped flexible plastic holder (fabricated using a nonconductive filament). The e-ring is modified with an electrodeposited gold film and is coupled to a miniature potentiostat directly addressable by a smartphone, offering the possibility for nonenzymatic amperometric self-testing of glucose levels in human sweat. Optical and electrochemical techniques are employed for the characterization of the e-ring. The device is resistant to mechanical bending and enables noninvasive glucose detection in sweat in the physiologically relevant concentration range of 12.5-400 μmol L^-1 without interference from common electroactive metabolites. The 3D-printed e-ring bridges the gap between the existing fabrication/sensing technologies and the desired operational features for glucose self-monitoring and may be employed as a paradigm of in-house fabricated wearable sensors.

Sensing of L-methionine in biological samples through fully 3D-printed electrodes

The variation in biomarkers levels, such as L-methionine, can be an indicator of health problems or diseases, such as metabolism, neuropsychiatric disorders, or some virus infections. Thus, the development of accurate sensors, with low-cost and rapid response has been gaining increasing importance and attractiveness for the early diagnosis of diseases. In this regard, we have proposed a method for L-methionine electrochemical detection using a low-cost and simple arrangement of 3D-printed electrodes (working, reference, and auxiliary electrodes) based on polylactic acid/graphene filament (PLA-G), in which all electrodes were printed. The working electrode was chemically and electrochemically treated, showing a high electroactive area, with graphene edge plans exposure and better electron transfer when compared to the untreated electrode. An excellent analytical performance was obtained with a sensitivity of 0.176 μAL μmol^-1, a linear dynamic range of 5.0 μmol L^-1- 3000 μmol L^-1 and limit of detection of 1.39 μmol L^-1. The proposed device was successfully applied for L-methionine detection in spiked serum samples, showing satisfactory recovery values. This indicates the potentiality of the proposed arrangement of electrodes for the L-methionine detection in biological samples at different concentration levels.

Fabrication of a 3D-Printed Porous Junction for Ag|AgCl|gel-KCl Reference Electrode

Fused filament fabrication (FFF) is a 3D printing method that is attracting increased interest in the development of miniaturized electrochemical sensor systems due to its versatility, low cost, reproducibility, and capability for rapid prototyping. A key component of miniaturized electrochemical systems is the reference electrode (RE). However, reports of the fabrication of a true 3D-printed RE that exhibits stability to variations in the sample matrix remain limited. In this work, we report the development and characterization of a 3D-printed Ag|AgCl|gel-KCl reference electrode (3D-RE). The RE was constructed using a Ag|AgCl wire and agar-KCl layer housed in a watertight 3D-printed acrylonitrile butadiene styrene (ABS) casing. The novel feature of our electrode is a 3D-printed porous junction that protects the gel electrolyte layer from chloride ion leakage and test sample contamination while maintaining electrical contact with the sample solution. By tuning the 3D printing filament extrusion ratio (k), the porosity of the junction was adjusted to balance the reference electrode potential stability and impedance. The resulting 3D-RE demonstrated a stable potential, with a potential drift of 4.55 ± 0.46 mV over a 12-h period of continuous immersion in 0.1 M KCl, and a low impedance of 0.50 ± 0.11 kΩ. The 3D-RE was also insensitive to variations in the sample matrix and maintained a stable potential for at least 30 days under proper storage in 3 M KCl. We demonstrate the application of this 3D-RE in cyclic voltammetry and in pH sensing coupled with electrodeposited iridium oxide on a gold electrode. Our method offers a viable strategy for 3D printing a customizable true reference electrode that can be readily fabricated on demand and integrated into 3D-printed miniaturized electrochemical sensor systems.

Ready-to-use 3D-printed electrochemical cell for in situ voltammetry of immobilized microparticles and Raman spectroscopy

We report in this communication a ready-to-use fused deposition modeling (FDM) based 3D-printed spectroelectrochemical cell to perform for the first time voltammetry of immobilized microparticles (VIMP) and Raman spectroscopy in situ using acrylonitrile butadiene styrene (ABS) as the filament material for printing. The 3D-printed cell was applied to evaluate solid state electrochemical behavior of tadalafil as a proof-of-concept. Several advantages were achieved in the use of the developed device, such as less manipulation of the working electrode, monitoring the same region of the solid microparticles before and after electrochemical measurements, better control of the laser incidence, low-cost and low-time production. Furthermore, the device was printed in a single-step, without handling to assembly and it has an estimated material cost of approximately 2 $. The use of 3D-printing technology was significantly important to integrate Raman spectroscopic method with VIMP measurements and to support mechanism elucidation and characterization of the compounds with less manipulation of the working electrode, avoiding loss of solid products formed from electrochemical reactions.

The development of a fully integrated 3D printed electrochemical platform and its application to investigate the chemical reaction between carbon dioxide and hydrazine

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An integrated electrochemical platform was manufactured by bi-material 3D printing.

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It was applied to investigate the reaction between hydrazine and carbon dioxide.

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Experimental results were supported by finite-element method numerical simulations.

The combination of computer assisted design and 3D printing has recently enabled fast and inexpensive manufacture of customized ‘reactionware’ for broad range of electrochemical applications. In this work bi-material fused deposition modeling 3D printing is utilized to construct an integrated platform based on a polyamide electrochemical cell and electrodes manufactured from a polylactic acid-carbon nanotube conductive composite. The cell contains separated compartments for the reference and counter electrode and enables reactants to be introduced and inspected under oxygen-free conditions. The developed platform was employed in a study investigating the electrochemical oxidation of aqueous hydrazine coupled to its bulk reaction with carbon dioxide. The analysis of cyclic voltammograms obtained in reaction mixtures with systematically varied composition confirmed that the reaction between hydrazine and carbon dioxide follows 1/1 stoichiometry and the corresponding equilibrium constant amounts to (2.8 ± 0.6) × 10³. Experimental characteristics were verified by results of numerical simulations based on the finite-element-method.

3D-Printed Immunosensor Arrays for Cancer Diagnostics

Detecting cancer at an early stage of disease progression promises better treatment outcomes and longer lifespans for cancer survivors. Research has been directed towards the development of accessible and highly sensitive cancer diagnostic tools, many of which rely on protein biomarkers and biomarker panels which are overexpressed in body fluids and associated with different types of cancer. Protein biomarker detection for point-of-care (POC) use requires the development of sensitive, noninvasive liquid biopsy cancer diagnostics that overcome the limitations and low sensitivities associated with current dependence upon imaging and invasive biopsies. Among many endeavors to produce user-friendly, semi-automated, and sensitive protein biomarker sensors, 3D printing is rapidly becoming an important contemporary tool for achieving these goals. Supported by the widely available selection of affordable desktop 3D printers and diverse printing options, 3D printing is becoming a standard tool for developing low-cost immunosensors that can also be used to make final commercial products. In the last few years, 3D printing platforms have been used to produce complex sensor devices with high resolution, tailored towards researchers’ and clinicians’ needs and limited only by their imagination. Unlike traditional subtractive manufacturing, 3D printing, also known as additive manufacturing, has drastically reduced the time of sensor and sensor array development while offering excellent sensitivity at a fraction of the cost of conventional technologies such as photolithography. In this review, we offer a comprehensive description of 3D printing techniques commonly used to develop immunosensors, arrays, and microfluidic arrays. In addition, recent applications utilizing 3D printing in immunosensors integrated with different signal transduction strategies are described. These applications include electrochemical, chemiluminescent (CL), and electrochemiluminescent (ECL) 3D-printed immunosensors. Finally, we discuss current challenges and limitations associated with available 3D printing technology and future directions of this field.

Voltammetric Determination of Pb(II) by a Ca-MOF-Modified Carbon Paste Electrode Integrated in a 3D-Printed Device

In this work, a voltammetric method based on a metal organic framework (Ca-MOF)-modified carbon paste electrode for lead determination was developed. The MOF-based electrode was packed in a new type of 3D-printed syringe-type integrated device, which was entirely fabricated by a dual extruder 3D printer. After optimization of the operational parameters, a limit of detection of 0.26 µg L⁻¹ Pb(II) was achieved, which is lower than that of existing MOF-based lead sensors. The device was used for Pb(II) determination in fish feed and bottled water samples with high accuracy and reliability. The proposed sensor is suitable for on-site analyses and provides a low-cost integrated transducer for the ultrasensitive routine detection of lead in practical applications.

Sustainable Printed Electrochemical Platforms for Greener Analytics

The development of miniaturized electrochemical platforms holds considerable importance for the in situ analytical monitoring of clinical, environmental, food, and forensic samples. However, it is crucial to pay attention to the sustainability of materials chosen to fabricate these devices, in order to decrease the amount and the impact of waste coming from their production and use. In the framework of a circular economy and an environmental footprint reduction, the electrochemical sensor production technology must discover the potentiality of innovative approaches based on techniques and materials that can satisfy the needs of environmental-friendly and greener analytics. The aim of this review is to describe some of the printing technologies most used for sensor production, including screen-printing, inkjet-printing, and 3D-printing, and the low-impact materials that are recently proposed for these techniques, such as polylactic acid, cellulose, silk proteins, biochar.

3D-printing pen versus desktop 3D-printers: Fabrication of carbon black/polylactic acid electrodes for single-drop detection of 2,4,6-trinitrotoluene

The fabrication of carbon black/polylactic acid (PLA) electrodes using a 3D printing pen is presented and compared with electrodes obtained by a desktop fused deposition modelling (FDM) 3D printer. The 3D pen was used for the fast production of electrodes in two designs using customized 3D printed parts to act as template and guide the reproducible application of the 3D pen: (i) a single working electrode at the bottom of a 3D-printed cylindrical body and (ii) a three-electrode system on a 3D-printed planar substrate. Both devices were electrochemically characterized using the redox probe [Fe(CN)₆]^3-/4- via cyclic voltammetry, which presented similar performance to an FDM 3D-printed electrode or a commercial screen-printed carbon electrode (SPE) regarding peak-to-peak separation (ΔEp) and current density. The surface treatment of the carbon black/PLA electrodes fabricated by both 3D pen and FDM 3D-printing procedures provided substantial improvement of the electrochemical activity by removing excess of PLA, which was confirmed by scanning electron microscopic images for electrodes fabricated by both procedures. Structural defects were not inserted after the electrochemical treatment as shown by Raman spectra (i_D/i_G), which indicates that the use of 3D pen can replace desktop 3D printers for electrode fabrication. Inter-electrode precision for the best device fabricated using the 3D pen (three-electrode system) was 4% (n = 5) considering current density and anodic peak potential for the redox probe. This device was applied for the detection of 2,4,6-trinitrotoluene (TNT) via square-wave voltammetry of a single-drop of 100 μL placed upon the thee-electrode system, resulting in three reduction peaks commonly verified for TNT on carbon electrodes. Limit of detection of 1.5 μmol L^-1, linear range from 5 to 500 μmol L^-1 and RSD lower than 4% for 10 repetitive measurements of 100 μmol L^-1 TNT were obtained. The proposed devices can be reused after polishing on sandpaper generating new electrode surfaces, which is an extra advantage over chemically-modified electrochemical sensors applied for TNT detection.