Plasmonic Sensing with 3D Printed Optics

3D-printed biosensors in biomedical applications exploiting plasmonic phenomena and antibody self-assembled monolayers

In this work, a 3D-printed plasmonic chip based on a silver-gold bilayer was developed in order to enhance the optical response of the surface plasmon resonance (SPR) probe. More specifically, numerical and experimental results were obtained on the 3D-printed SPR platform based on a silver-gold bilayer. Then, the optimized probe's gold plasmonic interface was functionalized with a specific antibody directed against the p27Kip1 protein (p27), an important cell cycle regulator. The 3D-printed plasmonic biosensor was tested for p27 detection with good selectivity and a detection limit of 55 pM. The biosensor system demonstrated performance similar to commercially available ELISA (enzyme-linked immunoassay) kits, with several advantages, such as a wide detection range and a modular and simple-based architecture. The proposed biosensing technology offers flexible deployment options that are useful in disposable, low-cost, small-size, and simple-to-use biochips, envisaging future applications in experimental and biomedical research.

Stimuli-Responsive 3D Printable Conductive Hydrogel: A Step toward Regulating Macrophage Polarization and Wound Healing

Conductive hydrogels (CHs) are promising alternatives for electrical stimulation of cells and tissues in biomedical engineering. Wound healing and immunomodulation are complex processes that involve multiple cell types and signaling pathways. 3D printable conductive hydrogels have emerged as an innovative approach to promote wound healing and modulate immune responses. CHs can facilitate electrical and mechanical stimuli, which can be beneficial for altering cellular metabolism and enhancing the efficiency of the delivery of therapeutic molecules. This review summarizes the recent advances in 3D printable conductive hydrogels for wound healing and their effect on macrophage polarization. This report also discusses the properties of various conductive materials that can be used to fabricate hydrogels to stimulate immune responses. Furthermore, this review highlights the challenges and limitations of using 3D printable CHs for future material discovery. Overall, 3D printable conductive hydrogels hold excellent potential for accelerating wound healing and immune responses, which can lead to the development of new therapeutic strategies for skin and immune-related diseases.

Analysis of Plasmonic Sensors Performance Realized by Exploiting Different UV-Cured Optical Adhesives Combined with Plastic Optical Fibers

Polymer-based surface plasmon resonance (SPR) sensors can be used to realize simple, small-size, disposable, and low-cost biosensors for application in several fields, e.g., healthcare. The performance of SPR sensors based on optical waveguides can be changed by tuning several parameters, such as the dimensions and the shape of the waveguides, the refractive index of the core, and the metal nanofilms used to excite the SPR phenomenon. In this work, in order to develop, experimentally test, and compare several polymer-based plasmonic sensors, realized by using waveguides with different core refractive indices, optical adhesives and 3D printed blocks with a trench inside have been used. In particular, the sensors are realized by filling the blocks' trenches (with two plastic optical fibers located at the end of these) with different UV-cured optical adhesives and then covering them with the same bilayer to excite the SPR phenomenon. The developed SPR sensors have been characterized by numerical and experimental results. Finally, in order to propose photonic solutions for healthcare, a comparative analysis has been reported to choose the best sensor configuration useful for developing low-cost biosensors.

UV polymerization fabrication method for polymer composite based optical fiber sensors

Optical fiber (OF) sensors are critical optical devices with excellent sensing capabilities and the capacity to operate in remote and hostile environments. However, integrating functional materials and micro/nanostructures into the optical fiber systems for specific sensing applications has limitations of compatibility, readiness, poor control, robustness, and cost-effectiveness. Herein, we have demonstrated the fabrication and integration of stimuli-responsive optical fiber probe sensors using a novel, low-cost, and facile 3D printing process. Thermal stimulus-response of thermochromic pigment micro-powders was integrated with optical fibers by incorporating them into ultraviolet-sensitive transparent polymer resins and then printed via a single droplet 3D printing process. Hence, the thermally active polymer composite fibers were grown (additively manufactured) on top of the commercial optical fiber tips. Then, the thermal response was studied within the temperature range of (25-35 °C) and (25-31 °C) for unicolor and dual color pigment powders-based fiber-tip sensors, respectively. The unicolor (with color to colorless transition) and dual color (with color to color transition) powders-based sensors exhibited substantial variations in transmission and reflection spectra by reversibly increasing and decreasing temperatures. The sensitivities were calculated from the transmission spectra where average change in transmission spectra was recorded as 3.5% with every 1 °C for blue, 3% for red and 1% for orange-yellow thermochromic powders based optical fiber tip sensors. Our fabricated sensors are cost-effective, reusable, and flexible in terms of materials and process parameters. Thus, the fabrication process can potentially develop transparent and tunable thermochromic sensors for remote sensing with a much simpler manufacturing process compared to conventional and other 3D printing processes for optical fiber sensors. Moreover, this process can integrate micro/nanostructures as patterns on the optical fiber tips to increase sensitivity. The developed sensors may be employed as remote temperature sensors in biomedical and healthcare applications.

The Field Guide to 3D Printing in Optical Microscopy for Life Sciences

The maker movement has reached the optics labs, empowering researchers to create and modify microscope designs and imaging accessories. 3D printing has a disruptive impact on the field, improving accessibility to fabrication technologies in additive manufacturing. This approach is particularly useful for rapid, low-cost prototyping, allowing unprecedented levels of productivity and accessibility. From inexpensive microscopes for education such as the FlyPi to the highly complex robotic microscope OpenFlexure, 3D printing is paving the way for the democratization of technology, promoting collaborative environments between researchers, as 3D designs are easily shared. This holds the unique possibility of extending the open-access concept from knowledge to technology, allowing researchers everywhere to use and extend model structures. Here, it is presented a review of additive manufacturing applications in optical microscopy for life sciences, guiding the user through this new and exciting technology and providing a starting point to anyone willing to employ this versatile and powerful new tool.

Smart 3D Printed Hydrogel Skin Wound Bandages: A Review

Wounds are a major health concern affecting the lives of millions of people. Some wounds may pass a threshold diameter to become unrecoverable by themselves. These wounds become chronic and may even lead to mortality. Recently, 3D printing technology, in association with biocompatible hydrogels, has emerged as a promising platform for developing smart wound dressings, overcoming several challenges. 3D printed wound dressings can be loaded with a variety of items, such as antibiotics, antibacterial nanoparticles, and other drugs that can accelerate wound healing rate. 3D printing is computerized, allowing each level of the printed part to be fully controlled in situ to produce the dressings desired. In this review, recent developments in hydrogel-based wound dressings made using 3D printing are covered. The most common biosensors integrated with 3D printed hydrogels for wound dressing applications are comprehensively discussed. Fundamental challenges for 3D printing and future prospects are highlighted. Additionally, some related nanomaterial-based hydrogels are recommended for future consideration.

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.

Microstructured Surface Plasmon Resonance Sensor Based on Inkjet 3D Printing Using Photocurable Resins with Tailored Refractive Index

In this work, a novel approach to realize a plasmonic sensor is presented. The proposed optical sensor device is designed, manufactured, and experimentally tested. Two photo-curable resins are used to 3D print a surface plasmon resonance (SPR) sensor. Both numerical and experimental analyses are presented in the paper. The numerical and experimental results confirm that the 3D printed SPR sensor presents performances, in term of figure of merit (FOM), very similar to other SPR sensors made using plastic optical fibers (POFs). For the 3D printed sensor, the measured FOM is 13.6 versus 13.4 for the SPR-POF configuration. The cost analysis shows that the 3D printed SPR sensor can be manufactured at low cost (∼15 €) that is competitive with traditional sensors. The approach presented here allows to realize an innovative SPR sensor showing low-cost, 3D-printing manufacturing free design and the feasibility to be integrated with other optical devices on the same plastic planar support, thus opening undisclosed future for the optical sensor systems.

3D printing-based mirrored image component for seamless modular curved-edge displays

A facile method for designing and fabricating a concave mirror from a 3D printed mold is proposed for a seamless modular curved-edge display. The concave mirror is placed on the seam of modular curved-edge display, thereby reflecting images at the curved-edge area toward the observer direction. By investigating the concave mirror structures based on parametric modeling, we obtain a continuous image in a modular curved-edge display by optically concealing the seam. We also analyze the luminance distribution and the viewing angle of the seamless modular curved-edge display to show the capability of concealing the seam by the concave mirror.

Review of 3D-Printed functionalized devices for chemical and biochemical analysis

Recent developments in three-dimensional printing (3DP) have attracted the attention of analytical scientists interested in fabricating 3D devices having promising geometric functions to achieve desirable analytical performance. To break through the barrier of limited availability of 3DP materials and to extend the chemical reactivity and functionalities of devices manufactured using conventional 3DP, new approaches are being developed for the functionalization of 3D-printed devices for chemical and biochemical analysis. This Review discusses recent advances in the chemical functionalization schemes used in the main 3DP technologies, including (i) post-printing modification and surface immobilization of reactive substances on printed materials, (ii) pre-printing incorporation of reactive substances into raw printing materials, and (iii) combinations of both strategies, and their effects on the selectivity and/or sensitivity of related analytical methods. In addition, the state of the art of 3D-printed functionalized analytical devices for enzymatic derivatization and sensing, electrochemical sensing, and sample pretreatment applications are also reviewed, highlighting the importance of introducing new functional and functionalized materials to facilitate future 3DP-enabled manufacturing of multifunctional analytical devices.

Dual-mode surface plasmon resonance sensor chip using a grating 3D-printed prism

The method for fabricating a grating prism surface plasmon resonance (SPR) sensor chip was developed. The grating prism was 3D-printed by a stereolithography 3D printer and subsequently created a grating pattern by soft lithography. A gold film was thermally evaporated on the grating prism. Moreover, a liquid cell was 3D-printed and assembled into a gold-coated grating prism. To make the sensor chip compact and practical, a compatible prism holder was 3D-printed by a fused deposition model 3D printer. The SPR sensor chip was mounted on the rotation stage and the SPR spectrum was recorded by spectrometer. The SPR excitation of the sensor chip can be extended to the near-infrared region by creating a grating pattern on the prism surface. A gold-coated grating prism exhibited dual modes of SPR excitations, namely, prism-coupling SPR (PC-SPR) and grating-coupling SPR (GC-SPR). The dual-mode SPR excitation was observed at the incident angles of 45°-80°. When the incident angle increased, the SPR excitation of the PC-SPR mode exhibited a blue shift in the wavelength region of 480-690 nm, whereas the GC-SPR mode exhibited a red shift in the wavelength region of 670-770 nm. The surface plasmon (SP) dispersion obtained from the dual-mode SPR configuration confirmed observable PC-SPR (which corresponded to + SP⁰ of the gold-resin interface) and GC-SPR (which corresponded to -SP⁺¹ of the gold-air interface), which could be excited from the developed substrate. The refractive index sensitivities of the PC-SPR and GC-SPR modes were 2924.4 and 414.9 nm RIU^-1, respectively. The SPR excitations of the sensor chip exhibited a simultaneous shift when the local refractive index of the materials adjacent to the gold-coated grating prism surface was changed, especially the material that had overlapping light absorption at the SPR excitation wavelength. Using this fabrication process, the prism is designed and then printed; moreover, the grating pattern on the prism surface can be employed to tune the SPR excitation wavelength of the sensor chip for the versatility and broad perspective of the optical sensing-based SPR.

Sealing 3D-printed parts to poly(dimethylsiloxane) for simple fabrication of Microfluidic devices

Microfluidics has revolutionized the fields of bioanalytical chemistry, cellular biology, and molecular biology. Advancements in microfluidic technologies, however, are often limited by labor, time, and resource-intensive fabrication methods, most commonly a form of photolithography. The advent of 3D printing has helped researchers fabricate proof-of-concept microfluidics more rapidly and at lower costs but suffers from poor resolution and tedious post-processing to remove uncured resin from enclosed channels. Additionally, custom resins and printers are often needed to create entirely enclosed channels, which increases cost and complexity of fabrication. In this work we demonstrate the ability to create microfluidic devices by covalently sealing 3D-printed parts with open-faced channels to polydimethylsiloxane (PDMS). Open-faced channels are easier to print than fully enclosed channels and can be printed using an inexpensive and commercially available stereolithography 3D printer and resin. The 3D-printed parts are sealed to PDMS, a common substrate used in traditional microfluidic fabrication, using two different techniques. The first involves coating the part with a commercially available silicone spray before sealing to PDMS via plasma treatment. In the second technique, the cured methacrylate resin is silanized with (3-Aminopropyl)triethoxysilane (APTES) before binding to PDMS with plasma treatment. Both methods create a strong seal between the two substrates, which is demonstrated with several types of microfluidic devices including droplet and gradient generators.

Antifouling Lipid Membranes over Protein A for Orientation-Controlled Immunosensing in Undiluted Serum and Plasma

An important advance in biosensor research is the extension and application of laboratory-developed methodologies toward clinical diagnostics, though the propensity toward nonspecific binding of materials in clinically relevant matrices, such as human blood serum and plasma, frequently leads to compromised assays. Several surface chemistries have been developed to minimize nonspecific interactions of proteins and other biological components found within blood and serum samples, though these often exhibit substantially variable outcomes. Herein we report a surface chemistry consisting of a charged-matched supported lipid membrane that has been tailored to form over a gold surface functionalized with protein A. Fine tuning of the interfacial charge of this membrane, along with rational selection of a backfilling self-assembled monolayer, allows for high surface coverage with retention of orientation-controlled capture antibody attachment. We demonstrate using surface-plasmon resonance (SPR) that this highly charged lipid membrane is antifouling, allowing for complete removal of nonspecific human serum and plasma components using only a mild buffer rinse, which we attribute to unique steric interactions with the underlying surface. Furthermore, this surface chemistry is successfully applied for specific detection of IgG and cholera toxin in undiluted human biofluids with negligible sacrifice of SPR signal compared to buffered analysis. This novel lipid membrane interface over protein A may open new avenues for direct biosensing of disease markers within clinical samples.

3D Printed Sensors for Biomedical Applications: A Review

This paper showcases a substantial review on some of the significant work done on 3D printing of sensors for biomedical applications. The importance of 3D printing techniques has bloomed in the sensing world due to their essential advantages of quick fabrication, easy accessibility, processing of varied materials and sustainability. Along with the introduction of the necessity and influence of 3D printing techniques for the fabrication of sensors for different healthcare applications, the paper explains the individual methodologies used to develop sensing prototypes. Six different 3D printing techniques have been explained in the manuscript, followed by drawing a comparison between them in terms of their advantages, disadvantages, materials being processed, resolution, repeatability, accuracy and applications. Finally, a conclusion of the paper is provided with some of the challenges of the current 3D printing techniques about the developed sensing prototypes, their corresponding remedial solutions and a market survey determining the expenditure on 3D printing for biomedical sensing prototypes.

Fabrication of Miniature Surface Plasmon Resonance Sensor Chips by Using Confined Sessile Drop Technique

In this study, we demonstrate a simple and efficient method to fabricate miniature surface plasmon resonance (SPR) sensor chips by using confined sessile drop technique. A liquid optical adhesive (NOA 61) was dropped on the circular flat surface of cylindrical substrates made of poly(dimethylsiloxane) (PDMS). The formation of hemispherical optical prisms was accomplished by taking advantage of the sharp edges of cylindrical PDMS substrates that prevented the overflow of liquid NOA 61 at the edge of substrates. The size of the hemispherical optical prisms can be controlled by changing the diameter of the cylindrical PDMS substrates. After UV curing, the SPR sensor chips were obtained by the deposition of 3 nm thick chromium and 47 nm thick gold on the flat side of the prisms. The fabricated miniature SPR sensor chips were then mounted on a three-dimensional-printed flow cell to complete the microfluidic SPR sensor module. The miniature SPR sensor chips provided a comparable sensitivity to the conventional high-refractive-index glass SPR chips. To demonstrate the detection capability of nanometer-sized materials, we applied the miniature microfluidic SPR system for monitoring the deposition of layer-by-layer ultrathin films of poly(diallyldimethylammonium chloride)/poly(sodium 4-styrenesulfonate) and for detecting human immunoglobulin G.

Advances in Optical Sensing and Bioanalysis Enabled by 3D Printing

The recent explosion of 3D printing applications in scientific literature has expanded the speed and effectiveness of analytical technological development. 3D printing allows for manufacture that is simply designed in software and printed in-house with nearly no constraints on geometry, and analytical methodologies can thus be prototyped and optimized with little difficulty. The versatility of methods and materials available allows the analytical chemist or biologist to fine-tune both the structural and functional portions of their apparatus. This flexibility has more recently been extended to optical-based bioanalysis, with higher resolution techniques and new printing materials opening the door for a wider variety of optical components, plasmonic surfaces, optical interfaces, and biomimetic systems that can be made in the laboratory. There have been discussions and reviews of various aspects of 3D printing technologies in analytical chemistry; this Review highlights recent literature and trends in their applications to optical sensing and bioanalysis.

3D-Printed Biosensor Arrays for Medical Diagnostics

While the technology is relatively new, low-cost 3D printing has impacted many aspects of human life. 3D printers are being used as manufacturing tools for a wide variety of devices in a spectrum of applications ranging from diagnosis to implants to external prostheses. The ease of use, availability of 3D-design software and low cost has made 3D printing an accessible manufacturing and fabrication tool in many bioanalytical research laboratories. 3D printers can print materials with varying density, optical character, strength and chemical properties that provide the user with a vast array of strategic options. In this review, we focus on applications in biomedical diagnostics and how this revolutionary technique is facilitating the development of low-cost, sensitive, and often geometrically complex tools. 3D printing in the fabrication of microfluidics, supporting equipment, and optical and electronic components of diagnostic devices is presented. Emerging diagnostics systems using 3D bioprinting as a tool to incorporate living cells or biomaterials into 3D printing is also reviewed.

Automated 3D-Printed Microfluidic Array for Rapid Nanomaterial-Enhanced Detection of Multiple Proteins

We report here the fabrication and validation of a novel 3D-printed, automated immunoarray to detect multiple proteins with ultralow detection limits. This low cost, miniature immunoarray employs electrochemiluminescent (ECL) detection measured with a CCD camera and employs touch-screen control of a micropump to facilitate automated use. The miniaturized array features prefilled reservoirs to deliver sample and reagents to a paper-thin pyrolytic graphite microwell detection chip to complete sandwich immunoassays. The detection chip achieves high sensitivity by using single-wall carbon nanotube-antibody conjugates in the microwells and employing massively labeled antibody-decorated RuBPY-silica nanoparticles to generate ECL. The total cost of an array is $0.65, and an eight-protein assay can be done in duplicate for $0.14 per protein with limits of detection (LOD) as low as 78-110 fg mL-1 in diluted serum. The electronic control system costs $210 in components. Utility of the automated immunoarray was demonstrated by detecting an eight-protein prostate cancer biomarker panel in human serum samples in 25 min. The system is well suited to future clinical and point-of-care diagnostic testing and could be used in resource-limited environments.

Plasmonic molecular assays: Recent advances and applications for mobile health

Plasmonics-based biosensing assays have been extensively employed for biomedical applications. Significant advancements in use of plasmonic assays for the construction of point-of-care (POC) diagnostic methods have been made to provide effective and urgent health care of patients, especially in resourcelimited settings. This rapidly progressive research area, centered on the unique surface plasmon resonance (SPR) properties of metallic nanostructures with exceptional absorption and scattering abilities, has greatly facilitated the development of cost-effective, sensitive, and rapid strategies for disease diagnostics and improving patient healthcare in both developed and developing worlds. This review highlights the recent advances and applications of plasmonic technologies for highly sensitive protein and nucleic acid biomarker detection. In particular, we focus on the implementation and penetration of various plasmonic technologies in conventional molecular diagnostic assays, and discuss how such modification has resulted in simpler, faster, and more sensitive alternatives that are suited for point-of-use. Finally, integration of plasmonic molecular assays with various portable POC platforms for mobile health applications are highlighted.

Developing Microfluidic Sensing Devices Using 3D Printing

This short perspective assesses the present landscape for desktop 3D printing to design and fabricate sensors, in particular, those associated with microfluidics and multiplexing. Lots of advanced devices have already been reported, and this article briefly surveys interesting achievements. Microfluidics can be designed and optimized faster and more easily on low cost desktop 3D printers that with competing methods. Rapid prototyping leads directly to a final (marketable) product fabricated on the same 3D printer. While resolution is not as good as lithographic approaches, very often channel and feature resolution on the order of 100 μm obtainable with SLA 3D printers is perfectly suitable for the desired sensing device. Two examples from our team's research are used to illustrate how using a 3D printer along with simple automation can reduce a complex microfluidic sensing procedure to a much simpler automated one. Future possibilities for sensor technology are discussed.