Fabrication of soft gold microelectrode arrays as probes for scanning electrochemical microscopy

Microarray-Based Electrochemical Biosensing

Microarrays are widely utilized in bioanalysis. Electrochemical biosensing techniques are often applied in microarray-based assays because of their simplicity, low cost, and high sensitivity. In such systems, the electrodes and sensing elements are arranged in arrays, and the target analytes are detected electrochemically. These sensors can be utilized for high-throughput bioanalysis and the electrochemical imaging of biosamples, including proteins, oligonucleotides, and cells. In this chapter, we summarize recent progress on these topics. We categorize electrochemical biosensing techniques for array detection into four groups: scanning electrochemical microscopy, electrode arrays, electrochemiluminescence, and bipolar electrodes. For each technique, we summarize the key principles and discuss the advantages, disadvantages, and bioanalysis applications. Finally, we present conclusions and perspectives about future directions in this field.

A Brief Review of In Situ and Operando Electrochemical Analysis of Bacteria by Scanning Probes

Bacteria are similar to social organisms that engage in critical interactions with one another, forming spatially structured communities. Despite extensive research on the composition, structure, and communication of bacteria, the mechanisms behind their interactions and biofilm formation are not yet fully understood. To address this issue, scanning probe techniques such as atomic force microscopy (AFM), scanning electrochemical microscopy (SECM), scanning electrochemical cell microscopy (SECCM), and scanning ion-conductance microscopy (SICM) have been utilized to analyze bacteria. This review article focuses on summarizing the use of electrochemical scanning probes for investigating bacteria, including analysis of electroactive metabolites, enzymes, oxygen consumption, ion concentrations, pH values, biofilms, and quorum sensing molecules to provide a better understanding of bacterial interactions and communication. SECM has been combined with other techniques, such as AFM, inverted optical microscopy, SICM, and fluorescence microscopy. This allows a comprehensive study of the surfaces of bacteria while also providing more information on their metabolic activity. In general, the use of scanning probes for the detection of bacteria has shown great promise and has the potential to provide a powerful tool for the study of bacterial physiology and the detection of bacterial infections.

Print-Light-Synthesis for Single-Step Metal Nanoparticle Synthesis and Patterned Electrode Production

The fabrication of thin-film electrodes, which contain metal nanoparticles and nanostructures for applications in electrochemical sensing as well as energy conversion and storage, is often based on multi-step procedures that include two main passages: (i) the synthesis and purification of nanomaterials and (ii) the fabrication of thin films by coating electrode supports with these nanomaterials. The patterning and miniaturization of thin film electrodes generally require masks or advanced patterning instrumentation. In recent years, various approaches have been presented to integrate the spatially resolved deposition of metal precursor solutions and the rapid conversion of the precursors into metal nanoparticles. To achieve the latter, high intensity light irradiation has, in particular, become suitable as it enables the photochemical, photocatalytical, and photothermal conversion of the precursors during or slightly after the precursor deposition. The conversion of the metal precursors directly on the target substrates can make the use of capping and stabilizing agents obsolete. This review focuses on hybrid platforms that comprise digital metal precursor ink printing and high intensity light irradiation for inducing metal precursor conversions into patterned metal and alloy nanoparticles. The combination of the two methods has recently been named Print-Light-Synthesis by a group of collaborators and is characterized by its sustainability in terms of low material consumption, low material waste, and reduced synthesis steps. It provides high control of precursor loading and light irradiation, both affecting and improving the fabrication of thin film electrodes.

Flexible Disk Ultramicroelectrode for High-Resolution and Substrate-Tolerable Scanning Electrochemical Microscopy Imaging

A simple and universal strategy for fabricating flexible 25 μm platinum (Pt) disk ultramicroelectrodes (UMEs) was proposed, where a pulled borosilicate glass micropipette acted as a mold for shaping the flexible tip with flexible epoxy resin. The whole preparation procedure was highly efficient, enabling 10 or more probes to be manually fabricated within 10 h. Intriguingly, this technique permits an adjustable RG ratio, tip length, and stiffness, which could be tuned according to varying experimental demands. Besides, the electroactive area of the probe could be exposed and made renewable with a thin blade, allowing its reuse in multiple experiments. The flexibility characterization was then employed to optimize the resin/hardener mass ratio of epoxy resin and the tip position during HF etching in the fabrication process, suggesting that more hardener, a larger RG value, or a longer tip length obtained stronger deformation resistance. Subsequently, the as-prepared probe was examined by optical microscopy, cyclic voltammetry, and SECM approach curves. The results demonstrated the probe possessed good geometry with a small RG ratio of less than 3 and exceptional electrochemical properties, and its insulating sheath remained undeformed after blade cutting. Owing to the tip's flexibility, it could be operated in contactless mode with an extremely low working distance and even in contact mode scanning to achieve high spatial resolution and high sensitivity while guaranteeing that the tip and samples would suffer minimal damage if the tip crashed. Finally, the flexible probe was successfully employed in three scanning scenarios where tilted and 3D structured PDMS microchips, a latent fingerprint deposited on the stiff copper sheet, and soft egg white were included. In all, the flexible probe encompasses the advantages of traditional disk UMEs and circumvents their principal drawbacks of tip crash and causing sample scratches, which is thus more compatible with large specimens of 3D structured, stiff, or even soft topography.

Compressed Sensing Image Reconstruction of Scanning Electrochemical Microscopy Measurements Carried Out at Ultrahigh Scan Speeds Using Continuous Line Probes

Previous studies on scanning electrochemical microscopy (SECM) imaging with nonlocal continuous line probes (CLPs) have demonstrated the ability to increase areal imaging rates by an order of magnitude compared to SECM based on conventional ultramicroelectrode (UME) disk electrodes. Increasing the linear scan speed of the CLP during imaging presents an opportunity to increase imaging rates even further but results in a significant deterioration in image quality due to transport processes in the liquid electrolyte. Here, we show that compressed sensing (CS) postprocessing can be successfully applied to CLP-based SECM measurements to reconstruct images with minimal distortion at probe scan rates greatly exceeding the conventional SECM ″speed limit″. By systematically evaluating the image quality of images generated by adaptable postprocessing CS methods for CLP-SECM data collected at varying scan rates, this work establishes a new upper bound for CLP scan rates. While conventional SECM imaging typically uses probe scan speeds characterized by Péclet numbers (Pe) < 1, this study shows that CS postprocessing methods can allow for an accurate image reconstruction for Pe approaching 5, corresponding to an order of magnitude increase in the maximum probe scan speed. This upper limit corresponds to the onset of chaotic convective flows within the electrolyte for the probes investigated in this work, highlighting the importance of considering hydrodynamics in the design of fast-scanning probes.

Design and operation of a scanning electrochemical microscope for imaging with continuous line probes

This article describes a home-built scanning electrochemical microscope capable of achieving high areal imaging rates through the use of continuous line probes (CLPs) and compressed sensing (CS) image reconstruction. The CLP is a nonlocal probe consisting of a band electrode, where the achievable spatial resolution is set by the thickness of the band and the achievable imaging rate is largely determined by its width. A combination of linear and rotational motors allows for CLP scanning at different angles over areas up to 25 cm² to generate the raw signal necessary to reconstruct the desired electrochemical image using CS signal analysis algorithms. Herein, we provide detailed descriptions of CLP fabrication, microscope design, and the procedures used to carry out scanning electrochemical microscopy imaging with CLPs. In order to illustrate the basic operating procedures for the microscope, line scans and images measured in the substrate generation-probe-collection mode for flat samples containing platinum disk electrodes are presented. These exemplary measurements illustrate methods for calibrating the positioning system, positioning and cleaning the CLP, and verifying proper positioning/probe sensitivity along its length.

Hybrid Machine Learning Method to Determine the Optimal Operating Process Window in Aerosol Jet 3D Printing

Aerosol jet printing (AJP) is a three-dimensional (3D) noncontact and direct printing technology for fabricating customized microelectronic devices on flexible substrates. Despite the capability of fine feature deposition, the complicated relationship between the main process parameters will affect the printing quality significantly in a design space. In this paper, a novel hybrid machine learning method is proposed to determine the optimal operating process window for the AJP process in various design spaces. The proposed method consists of classic machine learning methods, including experimental sampling, data clustering, classification, and knowledge transfer. In the proposed method, a two-dimensional design space is fully explored by a Latin hypercube sampling experimental design at a certain print speed. Then, the influence of the sheath gas flow rate (SHGFR) and the carrier gas flow rate (CGFR) on the printed line quality is analyzed by a K-means clustering approach, and an optimal operating process window is determined by a support vector machine. To efficiently identify more operating process windows at different print speeds, a transfer learning approach is applied to exploit relatedness between different operating process windows. Hence, at a new print speed, the number of line samples for identifying a new operating process window is greatly reduced. Finally, to balance the complex relationship among SHGFR, CGFR, and print speed, a 3D operating process window is determined by an incremental classification approach. Different from experiment-based approaches adopted in 3D printing technologies for quality optimization, the proposed method is developed based on the theory of knowledge discovery and data mining. Therefore, the knowledge in different design spaces can be fully explored and transferred for printed line quality optimization. Moreover, the data-driven-based characteristics can help the proposed method develop a guideline for quality optimization in other 3D printing technologies.

Micro/nanoelectrochemical probe and chip devices for evaluation of three-dimensional cultured cells

Herein, we present an overview of recent research progress in the development of micro/nanoelectrochemical probe and chip devices for the evaluation of three-dimensional (3D) cultured cells. First, we discuss probe devices: a general outline, evaluation of O₂ consumption, enzyme-modified electrodes, evaluation of endogenous enzyme activity, and the collection of cell components from cell aggregates are discussed. The next section is focused on integrated chip devices: a general outline, electrode array devices, smart electrode array devices, droplet detection of 3D cultured cells, cell manipulation using dielectrophoresis (DEP), and electrodeposited hydrogels used for fabrication of 3D cultured cells on chip devices are discussed. Finally, we provide a summary and discussion of future directions of research in this field.

Effect of Electrode Shape and Flow Conditions on the Electrochemical Detection with Band Microelectrodes

In this work, we report the analysis of the electrochemical detection of electroactive species with band microelectrodes that operate under controlled convection. The study focuses on the determination of the collection efficiency of the analyte as a function of inlet flow velocity and microband geometry (inlaid, bumped and recessed), also providing a straightforward method for the theoretical determination of the lower detection limit. The analysis has been carried out by simulating the dimensionless mass transport with the finite element method, delivering the stationary limiting current density. Simulations have been performed on systems consisting of single and double band electrodes to investigate the trail effect on the electrochemical detection. We show that the obtained dimensionless results can be easily turned into dimensional data, providing a tool for the design of devices. The proposed method is general and can easily be extended to systems with different geometry.

Polymers for 3D Printing and Customized Additive Manufacturing

Additive manufacturing (AM) alias 3D printing translates computer-aided design (CAD) virtual 3D models into physical objects. By digital slicing of CAD, 3D scan, or tomography data, AM builds objects layer by layer without the need for molds or machining. AM enables decentralized fabrication of customized objects on demand by exploiting digital information storage and retrieval via the Internet. The ongoing transition from rapid prototyping to rapid manufacturing prompts new challenges for mechanical engineers and materials scientists alike. Because polymers are by far the most utilized class of materials for AM, this Review focuses on polymer processing and the development of polymers and advanced polymer systems specifically for AM. AM techniques covered include vat photopolymerization (stereolithography), powder bed fusion (SLS), material and binder jetting (inkjet and aerosol 3D printing), sheet lamination (LOM), extrusion (FDM, 3D dispensing, 3D fiber deposition, and 3D plotting), and 3D bioprinting. The range of polymers used in AM encompasses thermoplastics, thermosets, elastomers, hydrogels, functional polymers, polymer blends, composites, and biological systems. Aspects of polymer design, additives, and processing parameters as they relate to enhancing build speed and improving accuracy, functionality, surface finish, stability, mechanical properties, and porosity are addressed. Selected applications demonstrate how polymer-based AM is being exploited in lightweight engineering, architecture, food processing, optics, energy technology, dentistry, drug delivery, and personalized medicine. Unparalleled by metals and ceramics, polymer-based AM plays a key role in the emerging AM of advanced multifunctional and multimaterial systems including living biological systems as well as life-like synthetic systems.

Microfabricated, Massive Electrochemical Arrays of Uniform Ultramicroelectrodes

We report the preparation and electrochemical characterization of massive electrochemical arrays containing as many as 110,000 highly uniform ultramicroelectrodes (UMEs). These arrays were microfabricated using conventional photolithography techniques on a gold-coated silicon chip in a simple three-step method. Photoresist polymer was used as an effective insulating matrix to define 2 μm, 3 μm, and 4 μm diameter circular UMEs across a 1 × 1 mm² area. The UME arrays are high uniform and contain tens of thousands of active disk-shape UMEs slightly recessed in thin films of photoresist. These arrays were tested with cyclic voltammetry and copper electrodeposition to assess the adhesion of photoresist to the gold surface as well as to examine their electrochemical activity. Numerical simulations were performed to further validate their electrochemical response. These UME arrays can be a useful platform for fundamental understanding molecular transport in uniform electrochemical arrays and designing highly-sensitive electroanalytical sensors.

A potentiostat featuring an integrator transimpedance amplifier for the measurement of very low currents--Proof-of-principle application in microfluidic separations and voltammetry

This work reports the design and construction of a novel potentiostat which features an integrator transimpedance amplifier as a current-monitoring unit. The integration approach addresses the limitations of the feedback resistor approach used for current monitoring in conventional potentiostat designs. In the present design, measurement of the current is performed by a precision switched integrator transimpedance amplifier operated in the dual sampling mode which enables sub-pA resolution. The potentiostat is suitable for measuring very low currents (typical dynamic range: 5 pA-4.7 μA) with a 16 bit resolution, and it can support 2-, 3- and 4-electrode cell configurations. Its operation was assessed by using it as a detection module in a home-made capillary electrophoresis system for the separation and amperometric detection of paracetamol and p-aminophenol at a 3-electrode microfluidic chip. The potential and limitations of the proposed potentiostat to implement fast potential-scan voltammetric techniques were demonstrated for the case of cyclic voltammetry.

Electrochemical push-pull probe: from scanning electrochemical microscopy to multimodal altering of cell microenvironment

To understand biological processes at the cellular level, a general approach is to alter the cells' environment and to study their chemical responses. Herein, we present the implementation of an electrochemical push-pull probe, which combines a microfluidic system with a microelectrode, as a tool for locally altering the microenvironment of few adherent living cells by working in two different perturbation modes, namely electrochemical (i.e., electrochemical generation of a chemical effector compound) and microfluidic (i.e., infusion of a chemical effector compound from the pushing microchannel, while simultaneously aspirating it through the pulling channel, thereby focusing the flow between the channels). The effect of several parameters such as flow rate, working distance, and probe inclination angle on the affected area of adherently growing cells was investigated both theoretically and experimentally. As a proof of concept, localized fluorescent labeling and pH changes were purposely introduced to validate the probe as a tool for studying adherent cancer cells through the control over the chemical composition of the extracellular space with high spatiotemporal resolution. A very good agreement between experimental and simulated results showed that the electrochemical perturbation mode enables to affect precisely only a few living cells localized in a high-density cell culture.

Optimization of aerosol jet printing for high-resolution, high-aspect ratio silver lines

Aerosol jet printing requires control of a number of process parameters, including the flow rate of the carrier gas that transports the aerosol mist to the substrate, the flow rate of the sheath gas that collimates the aerosol into a narrow beam, and the speed of the stage that transports the substrate beneath the beam. In this paper, the influence of process parameters on the geometry of aerosol-jet-printed silver lines is studied with the aim of creating high-resolution conductive lines of high current carrying capacity. A systematic study of process conditions revealed a key parameter: the ratio of the sheath gas flow rate to the carrier gas flow rate, defined here as the focusing ratio. Line width decreases with increasing the focusing ratio and stage speed. Simultaneously, the thickness increases with increasing the focusing ratio but decreases with increasing stage speed. Geometry control also influences the resistance per unit length and single pass printing of low-resistance silver lines is demonstrated. The results are used to develop an operability window and locate the regime for printing tall and narrow silver lines in a single pass. Under optimum conditions, lines as narrow as 20 μm with aspect ratios (thickness/width) greater than 0.1 are obtained.