Enhanced Performance Stability of Iridium Oxide-Based pH Sensors Fabricated on Rough Inkjet-Printed Platinum

Long-term stable pH sensor array with synergistic bilayer structure for 2D real-time mapping in cell culture monitoring

Pursuing accurate, swift, and durable pH sensors is important across numerous fields, encompassing healthcare, environmental surveillance, and agriculture. In particular, the emphasis on real-time pH monitoring during cell cultivation has become increasingly pronounced in the current scientific environment-a crucial element being diligently researched to ensure optimal cell production. Both polyaniline (PANi) and iridium oxide (IrOx) show their worth in pH sensing, yet they come with challenges. Single-PANi-layered pH sensors often grapple with diminished sensitivity and lagging responses, while electrodeposited IrOx structures exhibit poor adhesion, leading to their separation from metallic substrates-a trait undesirable for a consistently stable, long-term pH sensor. This paper introduces a bi-layered PANi-IrOx pH sensor, strategically leveraging the advantages of both materials. The results presented here underscore the sensitivity enhancement of binary-phased framework, faster response time, and more robust structure than prior work. Through this synergistic strategy, we demonstrate the potential of integrating different phases to overcome the inherent constraints of individual materials, setting the stage for advanced pH-sensing solutions.

Functionalized orthopaedic implant as pH electrochemical sensing tool for smart diagnosis of hardware infection

In the orthopaedic surgery field, the use of medical implants to treat a patient's bone fracture is nowadays a common practice, nevertheless, it is associated with possible cases of infection. The consequent hardware infection can lead to implant failure and systemic infections, with prolonged hospitalization, time-consuming rehabilitation treatments, and extended antibiotic therapy. Hardware infections are strictly related to bacterial adhesion to the implant, leading to infection occurrence and consequent pH decreasing from physiological level to acid pH. Here, we demonstrate the new strategy to use an orthopaedic implant functionalized with iridium oxide film as the working electrode for the potentiometric monitoring of pH in hardware infection diagnosis. A functional investigation was focused on selecting the implant material, namely titanium, titanium alloy, and stainless steel, and the component, namely screws and implants. After selecting the titanium-based implant as the working electrode and a silver wire as the reference electrode in the final configuration of the smart sensing orthopaedic implant, a calibration curve was performed in standard solutions. An equation equal to y = (0.76 ± 0.02) - (0.068 ± 0.002) x, R2 = 0.996, was obtained in the pH range of 4-8. Subsequently, hysteresis, interference, matrix effect, recovery study, and storage stability were investigated to test the overall performance of the sensing device, demonstrating the tremendous potential of electrochemical sensors to deliver the next generation of smart orthopaedic implants.

A paper-based dual functional biosensor for safe and user-friendly point-of-care urine analysis

Safe, accurate, and reliable analysis of urinary biomarkers is clinically important for early detection and monitoring of the progression of chronic kidney disease (CKD), as it has become one of the world's most prevalent non-communicable diseases. However, current technologies for measuring urinary biomarkers are either time-consuming and limited to well-equipped hospitals or lack the necessary sensitivity for quantitative analysis and post a health risk to frontline practitioners. Here we report a robust paper-based dual functional biosensor, which is integrated with the clinical urine sampling vial, for the simultaneous and quantitative analysis of pH and glucose in urine. The pH sensor was fabricated by electrochemically depositing IrOx onto a paper substrate using optimised parameters, which enabled an ultrahigh sensitivity of 71.58 mV pH-1. Glucose oxidase (GOx) was used in combination with an electrochemically deposited Prussian blue layer for the detection of glucose, and its performance was enhanced by gold nanoparticles (AuNPs), chitosan, and graphite composites, achieving a sensitivity of 1.5 μA mM-1. This dual function biosensor was validated using clinical urine samples, where a correlation coefficient of 0.96 for pH and 0.98 for glucose detection was achieved with commercial methods as references. More importantly, the urine sampling vial was kept sealed throughout the sample-to-result process, which minimised the health risk to frontline practitioners and simplified the diagnostic procedures. This diagnostic platform, therefore, holds high promise as a rapid, accurate, safe, and user-friendly point-of-care (POC) technology for the analysis of urinary biomarkers in frontline clinical settings.

An electrochemically cleanable pH electrode based on an electrodeposited iridium oxide-ruthenium oxide-titanium composite

Biological contamination is an important issue in environmental pH detection, and our prepared electrochemically cleanable electrode may be an effective solution. By electrodepositing an iridium oxide-ruthenium oxide composite on a titanium sheet substrate, the electrode shows a sensitivity of 59.4 mV per pH in the pH range of 2-12 with high reproducibility, low hysteresis, high selectivity and high stability. It is worth mentioning that the electrode was proved to be electrochemically cleanable from biological contamination. When the cleaning time was 30 minutes, the electrode sensitivity rose from 50 to 58 mV per pH. Furthermore, the pH sensor, assembled from the prepared iridium-ruthenium oxide electrode and a home-made Ag/AgCl electrode, has similar electrode properties to those of commercial glass electrodes, but is also mechanically strong and electrochemically cleanable, which is promising for long-term deployment in natural environments.

Integrated pH Sensors Based on RuO2/GO Nanocomposites Fabricated Using the Aerosol Jet Printing Method

An aerosol jet printing (AJP) process for depositing ruthenium dioxide (RuO2) as a promising material for pH sensing is reported. Graphene oxide (GO) with a large surface area was used for the in situ sol-gel deposition of RuO2 nanoparticles on its surface. The cosolvent ratio and solid loading of the solution are adjusted to form a printable and stable ink. The monodispersed aerosol was atomized on the surface of the screen-printed carbon electrode in order to develop an integrated pH sensor. The RuO2-GO pH sensor demonstrates excellent performance, with a rapid response time of less than 5 s and high sensitivity in the pH range of 4-10. Compared to traditional carbon electrodes, the RuO2-GO sensor shows up to four times higher sensitivity. The increased sensitivity is a result of the consistent attachment of small-crystallized RuO2 nanoparticles onto the surface of GO sheets, leading to a synergistic effect. Thanks to the AJP method as a facile and cost-effective integration technique, the fabricated electrodes can serve as an alternative to traditional rigid pH electrodes for accurate pH measurement.

Enhancing the repeatability and sensitivity of low-cost PCB, pH-sensitive field-effect transistors

Discrete, extended gate pH-sensitive field-effect transistors (dEGFETs) fabricated on printed circuit boards (PCBs) are a low-cost, simple to manufacture analytical technology that can be applied to a wide range of applications. Electrodeposited iridium oxide (IrOx) films have emerged as promising pH-sensitive layers owing to their theoretically high pH sensitivity and facile deposition, but typically exhibit low pH sensitivity or lack reproducibility. Moreover, to date, a combined IrOx and dEGFET PCB system has not yet been realised. In this study, we demonstrate a dEGFET pH sensor based on an extended gate manufactured on PCB that is rendered pH sensitive through an electrodeposited IrOx film, which can reliably and repeatably display beyond-Nernstian pH response. Using a combination of complementary surface analysis techniques, we show that the high pH sensitivity and repeatability of the dEGFETs are dependent on both the chemical composition and critically the uniformity of the IrOx film. The IrOx film uniformity can be enhanced through electrochemical polishing of the extended gate electrode prior to electrodeposition, leading to dEGFETs that exhibit a median pH sensitivity of 70.7 ± 5 mV/pH (n = 56) compared to only 31.3 ± 14 mV/pH (n = 31) for IrOx electrodeposited on non-polished PCB electrodes. Finally, we demonstrate the applicability of these devices by demonstrating the detection and quantification of ampicillin due to β-Lactamase enzyme activity, thus laying the foundation for cheap and ubiquitous sensors which can be applied to a range of global challenges across healthcare and environmental monitoring.

Conductive Inks Based on Melamine Intercalated Graphene Nanosheets for Inkjet Printed Flexible Electronics

With the growing number of flexible electronics applications, environmentally benign ways of mass-producing graphene electronics are sought. In this study, we present a scalable mechanochemical route for the exfoliation of graphite in a planetary ball mill with melamine to form melamine-intercalated graphene nanosheets (M-GNS). M-GNS morphology was evaluated, revealing small particles, down to 14 nm in diameter and 0.4 nm thick. The M-GNS were used as a functional material in the formulation of an inkjet-printable conductive ink, based on green solvents: water, ethanol, and ethylene glycol. The ink satisfied restrictions regarding stability and nanoparticle size; in addition, it was successfully inkjet printed on plastic sheets. Thermal and photonic post-print processing were evaluated as a means of reducing the electrical resistance of the printed features. Minimal sheet resistance values (5 kΩ/sq for 10 printed layers and 626 Ω/sq for 20 printed layers) were obtained on polyimide sheets, after thermal annealing for 1 h at 400 °C and a subsequent single intense pulsed light flash. Lastly, a proof-of-concept simple flexible printed circuit consisting of a battery-powered LED was realized. The demonstrated approach presents an environmentally friendly alternative to mass-producing graphene-based printed flexible electronics.

Recent advances in flexible and wearable sensors for monitoring chemical molecules

In recent years, real-time health management has received increasing attention, benefiting from the rapid development of flexible and wearable devices. Conventionally, flexible and wearable devices are used for collecting health data such as electrophysiological signals, blood pressure, heart rate, etc. The monitoring of chemical factors has shown growing significance, providing the basis for the screening, diagnosis, and treatment of many diseases. Nowadays, in order to understand the health status of the human body more comprehensively and accurately, researchers in the community have started putting effort into developing wearable devices for monitoring chemical factors. Progressively, more flexible chemical sensors with wearable real-time health-monitoring functionality have been developed thanks to advances relating to wireless communications and flexible electronics. In this review, we describe the variety of chemical molecules and information that can currently be monitored, including pH levels, glucose, lactate, uric acid, ion levels, cytokines, nutrients, and other biomarkers. This review analyzes the pros and cons of the most advanced wearable chemical sensors in terms of wearability. At the end of this review, we discuss the current challenges and development trends relating to flexible and wearable chemical sensors from the aspects of materials, electrode designs, and soft-hard interface connections.

High Resolution Patterning of an Organic-Inorganic Photoresin for the Fabrication of Platinum Microstructures

Platinum (Pt) is an interesting material for many applications due to its high chemical resilience, outstanding catalytic activity, high electrical conductivity, and high melting point. However, microstructuring and especially 3D microstructuring of platinum is a complex process, based on expensive and specialized equipment often suffering from very slow processing speeds. In this work, organic-inorganic photoresins, which can be structured using direct optical lithography as well as two-photon lithography (TPL) with submicrometer resolution and high-throughput is presented. The printed structures are subsequently converted to high-purity platinum using thermal debinding of the binder and reduction of the salt. With this technique, complex 3D structures with a 3D resolution of 300 nm were fabricated. At a layer thickness of 35 nm, the patterns reach a high conductivity of 67% compared to bulk platinum. Microheaters, thermocouple sensors as well as a Lab-on-a-Chip system are presented as exemplary applications. This technology will enable a broad range of application from electronics, sensing and heating elements to 3D photonics and metamaterials.

Specially Designed Polyaniline/Polypyrrole Ink for a Fully Printed Highly Sensitive pH Microsensor

pH sensing for healthcare applications requires sensors with mechanically stable materials of high sensitivity and high reproducibility combined with low-cost fabrication technologies. This work proposes a fully printed pH sensor based on a specially formulated conducting polymer deposited on a microelectrode in a flexible substrate. A formulation, which combined polyaniline (PANI) and polypyrrole (PPy) with integrated polyelectrolyte poly(sodium 4-styrenesulfonate) (PSS), was specially prepared to be printed by inkjet printing (IJP). The sensor has good sensitivity in the physiological region (pH 7-7.5) key for the healthcare biosensor. This mixture printed over a commercial gold ink, which has a singular chemical functionalization with phthalocyanine (Pc), increased the sensor sensitivity, showing an excellent reproducibility with a linear super-Nernstian response (81.2 ± 0.5 mV/pH unit) in a wide pH range (pH 3-10). This new ink together with the IJP low-cost technique opens new opportunities for pH sensing in the healthcare field with a single device, which is disposable, highly sensitive, and stable in the whole pH range.

Optimizing Aerosol Jet Printing Process of Platinum Ink for High-Resolution Conductive Microstructures on Ceramic and Polymer Substrates

Printing nano-ink with platinum nanoparticles to generate conductive microstructures for electronics on different types of substrates has gained increasing interest in recent years. To solve the problem of the low conductivity of platinum (Pt) nano-ink, we synthesized chemically pure Pt nanoparticles with sizes of 18.2 ± 9.0 nm by spark discharge method. A low toxic solvent, ethylene glycol with water, was used to ensure the aggregation stability of Pt nanoparticles. Polyvinylpyrrolidone was used as an adhesive additive and binder in the nano-ink. Narrow and conductive Pt lines were generated by aerosol jet printing technology. The resistivity of the Pt lines sintered at 750 °C on alumina substrate was found to exceed the bulk Pt by about 13%. Moreover, the Pt film fabricated on polymer substrates has demonstrated excellent mechanical flexibility in terms of twisting tests.

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.

Nanochannel Templated Iridium Oxide Nanostructures for Wide-Range pH Sensing from Solutions to Human Skin Surface

Herein we report the fabrication of highly sensitive solid-state pH sensors based on iridium oxide nanowires (IONWs) for a wide-range of pH measurements. IONWs were confined electrodeposits on the indium tin oxide (ITO) electrode using a highly ordered silica nanochannel membrane as the template. Subsequently removing the template produced amorphous IONWs consisting of hydrated iridium oxyhydroxides. The IONW/ITO sensor can rapidly respond to the pH of the aqueous solutions in a wide range (from 0 to 13), avoiding the acid and alkaline errors encountered by conventional pH electrodes and exhibiting a super-Nernst analytical sensitivity as high as 235.5 mV/pH in the very acidic range of ∼0-2.5 and 90.1 mV/pH beyond (pH = ∼2.5-13). The sensitivity was associated with the interconversion of oxidation states of iridium oxyhydroxides. While in the very acidic range, intercalation of Cl^- was proved to be responsible for the exceptionally high pH sensitivity. Moreover, the sensor was also demonstrated to work in organic solutions too. Finally, the flexible IONW/ITO electrode was prepared and interfaced to a wireless electrochemical device for real-time epidermal pH analysis with smartphones.

Stable Full-Inkjet-Printed Solid-State Ag/AgCl Reference Electrode

With a growing demand for the availability of inexpensive, simple, and rapid prototyped devices, the prospect of miniaturization of the reference electrodes using printing techniques becomes promising. A stable and reusable full-inkjet-printed solid-state reference electrode (IPRE) was developed. The reference electrode was fully produced by consecutive inkjet printing of several layers. Ag ink was printed and chlorinated by NaClO printing, forming a Ag/AgCl pseudoreference electrode. Then a surface protection by printing a Cl^--saturated polyvinyl butyral membrane finally gave a reference electrode that demonstrated an outstanding performance comparable to commercial ones. This full inkjet printing fabrication strategy will improve the viability of producing low-cost miniaturized reference electrodes with interest in many electrochemical sensor-dependent areas.

A Minimally Invasive Microsensor Specially Designed for Simultaneous Dissolved Oxygen and pH Biofilm Profiling

A novel sensing device for simultaneous dissolved oxygen (DO) and pH monitoring specially designed for biofilm profiling is presented in this work. This device enabled the recording of instantaneous DO and pH dynamic profiles within biofilms, improving the tools available for the study and the characterization of biological systems. The microsensor consisted of two parallel arrays of microelectrodes. Microelectrodes used for DO sensing were bare gold electrodes, while microelectrodes used for pH sensing were platinum-based electrodes modified using electrodeposited iridium oxide. The device was fabricated with a polyimide (Kapton^®) film of 127 µm as a substrate for minimizing the damage caused on the biofilm structure during its insertion. The electrodes were covered with a Nafion^® layer to increase sensor stability and repeatability and to avoid electrode surface fouling. DO microelectrodes showed a linear response in the range 0–8 mg L⁻¹, a detection limit of 0.05 mg L⁻¹, and a sensitivity of 2.06 nA L mg⁻¹. pH electrodes showed a linear super-Nernstian response (74.2 ± 0.7 mV/pH unit) in a wide pH range (pH 4−9). The multi-analyte sensor array was validated in a flat plate bioreactor where simultaneous and instantaneous pH and DO profiles within a sulfide oxidizing biofilm were recorded. The electrodes spatial resolution, the monitoring sensitivity, and the minimally invasive features exhibited by the proposed microsensor improved biofilm monitoring performance, enabling the quantification of mass transfer resistances and the assessment of biological activity.