3D Printing Technologies in Biosensors Production: Recent Developments

Inside out: Exploring edible biocatalytic biosensors for health monitoring

Edible biosensors can measure a wide range of physiological and biochemical parameters, including temperature, pH, gases, gastrointestinal biomarkers, enzymes, hormones, glucose, and drug levels, providing real-time data. Edible biocatalytic biosensors represent a new frontier within healthcare technology available for remote medical diagnosis. The main challenges to develop edible biosensors are: i) finding edible materials (i.e. redox mediators, conductive materials, binders and biorecognition elements such as enzymes) complying with Food and Drug Administration (FDA), European Food Safety Authority (EFSA) and European Medicines Agency (EMEA) regulations; ii) developing bioelectronics able to operate in extreme working conditions such as low pH (∼pH 1.5 gastric fluids etc.), body temperature (between 37 °C and 40 °C) and highly viscous bodily fluids that may cause surface biofouling issues. Nowadays, advanced printing techniques can revolutionize the design and manufacturing of edible biocatalytic biosensors. This review outlines recent research on biomaterials suitable for creating edible biocatalytic biosensors, focusing on their electrochemical properties such as electrical conductivity and redox potential. It also examines biomaterials as substrates for printing and discusses various printing methods, highlighting challenges and perspectives for edible biocatalytic biosensors.

Microbial Biofilms: Features of Formation and Potential for Use in Bioelectrochemical Devices

Microbial biofilms present one of the most widespread forms of life on Earth. The formation of microbial communities on various surfaces presents a major challenge in a variety of fields, including medicine, the food industry, shipping, etc. At the same time, this process can also be used for the benefit of humans-in bioremediation, wastewater treatment, and various biotechnological processes. The main direction of using electroactive microbial biofilms is their incorporation into the composition of biosensor and biofuel cells This review examines the fundamental knowledge acquired about the structure and formation of biofilms, the properties they have when used in bioelectrochemical devices, and the characteristics of the formation of these structures on different surfaces. Special attention is given to the potential of applying the latest advances in genetic engineering in order to improve the performance of microbial biofilm-based devices and to regulate the processes that take place within them. Finally, we highlight possible ways of dealing with the drawbacks of using biofilms in the creation of highly efficient biosensors and biofuel cells.

Portable IC system enabled with dual LED-based absorbance detectors and 3D-printed post-column heated micro-reactor for the simultaneous determination of ammonium, nitrite and nitrate

BACKGROUND

The on-site and simultaneous determination of anionic nitrite (NO2-) and nitrate (NO3-), and cationic ammonium (NH4+), in industrial and natural waters, presents a significant analytical challenge. Toward this end, herein a 3D-printed micro-reactor with an integrated heater chip was designed and optimised for the post-column colorimetric detection of NH4+ using a modified Berthelot reaction. The system was integrated within a portable and field deployable ion chromatograph (Aquamonitrix) designed to separate and detect NO2- and NO3-, but here enabled with dual LED-based absorbance detectors, with the aim to provide the first system capable of simultaneous determination of both anions and NH4+ in industrial and natural waters.

RESULTS

Incorporating a 0.750 mm I.D. 3D-printed serpentine-based microchannel for sample-reagent mixing and heating, the resultant micro-reactor had a total reactor channel length of 1.26 m, which provided for a reaction time of 1.42 min based upon a total flow rate of 0.27 mL min-1, within a 40 mm2 printed area. The colorimetric reaction was performed within the micro-reactor, which was then coupled to a dedicated 660 nm LED-based absorbance detector. By rapidly delivering a reactor temperature of 70 °C in just 40 s, the optimal conditions to improve reaction kinetics were achieved to provide for limits of detection of 0.1 mg L-1 for NH4+, based upon an injection volume of just 10 μL. Linearity for NH4+ was observed over the range 0-50 mg L-1, n = 3, R2 = 0.9987. The reactor was found to deliver excellent reproducibility when included as a post-column reactor within the Aquamonitrix analyser, with an overall relative standard deviation below 1.2 % for peak height and 0.3 % for peak residence time, based upon 6 repeat injections.

SIGNIFICANCE

The printed post-column reactor assembly was integrated into a commercial portable ion chromatograph developed for the separation and detection of NO2- and NO3-, thus providing a fully automated system for the remote and simultaneous analysis of NO2-, NO3-, and NH4+ in natural and industrial waters. The fully automated system was deployed externally within a greenhouse facility to demonstrate this capability.

Biosensing of multiple aromatic xenobiotics in water by in-house fabricated prototype device

Portable, low-cost, and accurate monitoring of hazardous mono-aromatic pollutants, such as phenol or benzene group of compounds in water is a challenging task due to the lack of suitable detectable functional groups and complex matrix of environmental samples. Here, we use a series of protein-based biosensing recognition scaffolds to enable specific detection of several mono-aromatic classes of xenobiotics. The biosensor is tuned to perform in intricate environmental conditions and is interfaced with an in-house manufactured, multi-channel device (AroTrack) capable of direct and sensitive detection of several of these aromatic contaminants, such as phenol, benzene, and 2,3-dimethylphenol (2,3-DMP) in the low ppb range (10-200 ppb). The efficiency of the prototype device was benchmarked in both simulated wastewater and real environmental samples comprising 10 times higher isostructural aromatic pollutants or ions. It was established that AroTrack is reliable for environmental sample testing with a high degree of reproducibility and efficiency comparable to that of modern spectrophotometers (<5 % error). The battery-operated device costs less than $50 to fabricate and this low cost makes it effective to be implemented in rural and low-income settings which suggests immense field deployable potential.

A review on the surface modification of materials for 3D-printed diagnostic devices

Three-dimensional (3D) printing in tissue engineering and biosensing of analytes by using biocompatible materials or modifying surface structures is an upcoming area of study. This review discusses three common surface modification techniques, viz. alkaline hydrolysis, UV light photografting, and plasma treatment. Alkaline hydrolysis involves the reaction of an alkaline solution with the surface of a material, causing the surface to develop carboxyl and hydroxyl groups. This technique can enhance the biocompatibility, surface wettability, adhesion, printability, and dyeability of materials, such as acrylonitrile butadiene styrene (ABS), polycarbonate, and polylactic acid (PLA). This review also mentions details about some of the surface-modified 3D-printed diagnostic devices. Although most of the devices are modified using chemical processes, there are always multiple techniques involved while designing a diagnostic device. We have, therefore, mentioned some of the devices based on the materials used instead of categorising them as per modification techniques. 3D printing helps in the design of sophisticated shapes and structures using multiple materials. They can, therefore be used even in the design of microfluidic devices that are very useful for biosensing. We have also mentioned a few materials for printing microfluidic devices.

The 3D Printing of Nanocomposites for Wearable Biosensors: Recent Advances, Challenges, and Prospects

Notably, 3D-printed flexible and wearable biosensors have immense potential to interact with the human body noninvasively for the real-time and continuous health monitoring of physiological parameters. This paper comprehensively reviews the progress in 3D-printed wearable biosensors. The review also explores the incorporation of nanocomposites in 3D printing for biosensors. A detailed analysis of various 3D printing processes for fabricating wearable biosensors is reported. Besides this, recent advances in various 3D-printed wearable biosensors platforms such as sweat sensors, glucose sensors, electrocardiography sensors, electroencephalography sensors, tactile sensors, wearable oximeters, tattoo sensors, and respiratory sensors are discussed. Furthermore, the challenges and prospects associated with 3D-printed wearable biosensors are presented. This review is an invaluable resource for engineers, researchers, and healthcare clinicians, providing insights into the advancements and capabilities of 3D printing in the wearable biosensor domain.

Use of 3D Printing Techniques to Fabricate Implantable Microelectrodes for Electrochemical Detection of Biomarkers in the Early Diagnosis of Cardiovascular and Neurodegenerative Diseases

This Review provides a comprehensive overview of 3D printing techniques to fabricate implantable microelectrodes for the electrochemical detection of biomarkers in the early diagnosis of cardiovascular and neurodegenerative diseases. Early diagnosis of these diseases is crucial to improving patient outcomes and reducing healthcare systems' burden. Biomarkers serve as measurable indicators of these diseases, and implantable microelectrodes offer a promising tool for their electrochemical detection. Here, we discuss various 3D printing techniques, including stereolithography (SLA), digital light processing (DLP), fused deposition modeling (FDM), selective laser sintering (SLS), and two-photon polymerization (2PP), highlighting their advantages and limitations in microelectrode fabrication. We also explore the materials used in constructing implantable microelectrodes, emphasizing their biocompatibility and biodegradation properties. The principles of electrochemical detection and the types of sensors utilized are examined, with a focus on their applications in detecting biomarkers for cardiovascular and neurodegenerative diseases. Finally, we address the current challenges and future perspectives in the field of 3D-printed implantable microelectrodes, emphasizing their potential for improving early diagnosis and personalized treatment strategies.

Conceptual Design and Numerical Validation of a Carbon-Based Ink Injector

This paper shows the design of an injector, using carbon nanotubes as inkjet material, implemented in a 3D printer. According to the available literature, few injectors are capable of depositing material. Due to the lack of information, the central part of this research is to develop a suitable device for ink injection that is capable of applying the Fused Deposition Modeling (FDM) method to print nanomaterial ink. The injector was designed using a CAD program based on an open-source desktop 3D printer, which allows it to be modified according to the needs of the injector. This prototype was manufactured in aluminum alloy 7075T6. Computational fluid dynamics (CFD) were carried out to analyze the behavior of the fluid when it passes through the injector, obtaining parameters such as pressure, velocity, and vorticity. An experimental matrix of the injector operation was carried out to achieve an adequate printing speed. The results show that the optimum speed was 250 ms, considering that a temperature of 100 °C is needed in the heated bed to dry the ink so that it does not undergo expansion.

Wearable Insulin Biosensors for Diabetes Management: Advances and Challenges

We present a critical review of the current progress in wearable insulin biosensors. For over 40 years, glucose biosensors have been used for diabetes management. Measurement of blood glucose is an indirect method for calculating the insulin administration dosage, which is critical for insulin-dependent diabetic patients. Research and development efforts aiming towards continuous-insulin-monitoring biosensors in combination with existing glucose biosensors are expected to offer a more accurate estimation of insulin sensitivity, regulate insulin dosage and facilitate progress towards development of a reliable artificial pancreas, as an ultimate goal in diabetes management and personalised medicine. Conventional laboratory analytical techniques for insulin detection are expensive and time-consuming and lack a real-time monitoring capability. On the other hand, biosensors offer point-of-care testing, continuous monitoring, miniaturisation, high specificity and sensitivity, rapid response time, ease of use and low costs. Current research, future developments and challenges in insulin biosensor technology are reviewed and assessed. Different insulin biosensor categories such as aptamer-based, molecularly imprinted polymer (MIP)-based, label-free and other types are presented among the latest developments in the field. This multidisciplinary field requires engagement between scientists, engineers, clinicians and industry for addressing the challenges for a commercial, reliable, real-time-monitoring wearable insulin biosensor.

3D-Printed Microfluidic Chip for Real-Time Glucose Monitoring in Liquid Analytes

The connection of macrosystems with microsystems for in-line measurements is important in different biotechnological processes as it enables precise and accurate monitoring of process parameters at a small scale, which can provide valuable insights into the process, and ultimately lead to improved process control and optimization. Additionally, it allows continuous monitoring without the need for manual sampling and analysis, leading to more efficient and cost-effective production. In this paper, a 3D printed microfluidic (MF) chip for glucose (Glc) sensing in a liquid analyte is proposed. The chip made in Poly(methyl methacrylate) (PMMA) contains integrated serpentine-based micromixers realized via stereolithography with a slot for USB-like integration of commercial DropSens electrodes. After adjusting the sample's pH in the first micromixer, small volumes of the sample and enzyme are mixed in the second micromixer and lead to a sensing chamber where the Glc concentration is measured via chronoamperometry. The sensing potential was examined for Glc concentrations in acetate buffer in the range of 0.1-100 mg/mL and afterward tested for Glc sensing in a cell culturing medium. The proposed chip showed great potential for connection with macrosystems, such as bioreactors, for direct in-line monitoring of a quality parameter in a liquid sample.

A 3D-Printed Capacitive Smart Insole for Plantar Pressure Monitoring

Gait analysis refers to the systematic study of human locomotion and finds numerous applications in the fields of clinical monitoring, rehabilitation, sports science and robotics. Wearable sensors for real-time gait monitoring have emerged as an attractive alternative to the traditional clinical-based techniques, owing to their low cost and portability. In addition, 3D printing technology has recently drawn increased interest for the manufacturing of sensors, considering the advantages of diminished fabrication cost and time. In this study, we report the development of a 3D-printed capacitive smart insole for the measurement of plantar pressure. Initially, a novel 3D-printed capacitive pressure sensor was fabricated and its sensing performance was evaluated. The sensor exhibited a sensitivity of 1.19 MPa−1, a wide working pressure range (<872.4 kPa), excellent stability and durability (at least 2.280 cycles), great linearity (R2=0.993), fast response/recovery time (142−160 ms), low hysteresis (DH<10%) and the ability to support a broad spectrum of gait speeds (30−70 steps/min). Subsequently, 16 pressure sensors were integrated into a 3D-printed smart insole that was successfully applied for dynamic plantar pressure mapping and proven able to distinguish the various gait phases. We consider that the smart insole presented here is a simple, easy to manufacture and cost-effective solution with the potential for real-world applications.

Recent Progresses in Development of Biosensors for Thrombin Detection

Thrombin is a serine protease with an essential role in homeostasis and blood coagulation. During vascular injuries, thrombin is generated from prothrombin, a plasma protein, to polymerize fibrinogen molecules into fibrin filaments. Moreover, thrombin is a potent stimulant for platelet activation, which causes blood clots to prevent bleeding. The rapid and sensitive detection of thrombin is important in biological analysis and clinical diagnosis. Hence, various biosensors for thrombin measurement have been developed. Biosensors are devices that produce a quantifiable signal from biological interactions in proportion to the concentration of a target analyte. An aptasensor is a biosensor in which a DNA or RNA aptamer has been used as a biological recognition element and can identify target molecules with a high degree of sensitivity and affinity. Designed biosensors could provide effective methods for the highly selective and specific detection of thrombin. This review has attempted to provide an update of the various biosensors proposed in the literature, which have been designed for thrombin detection. According to their various transducers, the constructions and compositions, the performance, benefits, and restrictions of each are summarized and compared.

Evaluation of Relative Permittivity and Loss Factor of 3D Printing Materials for Use in RF Electronic Applications

3D printing is more and more often used for the development and manufacturing of electronic devices and components. These applications require knowledge about the dielectric properties of the used materials—in particular minimal and stable values of relative permittivity and dielectric losses. The paper deals with the testing of the relative permittivity and loss factor of materials as follows: PLA (in three dye modifications), PET-G, and ABS and ASA in the frequency range 1–100 MHz. It was found that relative permittivity varied between 2.88–3.48 and the loss factor was in the range 0.03–4.31%. In terms of relative permittivity, all tested materials manifested a slight decline with increasing frequency. Concerning loss factor PLA (colorless) and ABS were proven to be more suitable for electrotechnical application due to the lower values and frequency dependences of the loss factor. Different results were observed in PLA-Silver and PLA-Metallic green. These materials showed a higher frequency dependency of loss factor with increasing frequency. The reasonable influence of added dyes was found. A study of the internal structure of the tested materials has not proven any significant defects (air gaps) that could affect the material’s dielectric properties.

Recent Advances in Electrochemical Sensing Strategies for Food Allergen Detection

Food allergy has been indicated as the most frequent adverse reaction to food ingredients over the past few years. Since the only way to avoid the occurrence of allergic phenomena is to eliminate allergenic foods, it is essential to have complete and accurate information on the components of foodstuff. In this framework, it is mandatory and crucial to provide fast, cost-effective, affordable, and reliable analysis methods for the screening of specific allergen content in food products. This review reports the research advancements concerning food allergen detection, involving electrochemical biosensors. It focuses on the sensing strategies evidencing different types of recognition elements such as antibodies, nucleic acids, and cells, among others, the nanomaterial role, the several electrochemical techniques involved and last, but not least, the ad hoc electrodic surface modification approaches. Moreover, a selection of the most recent electrochemical sensors for allergen detection are reported and critically analyzed in terms of the sensors’ analytical performances. Finally, advantages, limitations, and potentialities for practical applications of electrochemical biosensors for allergens are discussed.

Investigating electrochemical deposition of gold on commercial off-the-shelf 3-D printing materials towards developing sensing applications†

The COVID-19 pandemic highlighted the inaccessibility of quick and affordable clinical diagnostics. This led to increased interest in creating low-cost portable electrochemical (EC) devices for environmental monitoring and clinical diagnostics. One important perspective is to develop new fabrication methods for functional and low-cost electrode chips. Techniques, such as electron beam and photolithography, allow precise and high-resolution electrode fabrication; however, they are costly and can be time-consuming. More recently, fused deposition modeling three-dimensional (3-D) printing is being used as an alternative fabrication technique due to the low-cost of the printer and rapid prototyping capability. In this study, we explore enhancing the conductivity of 3-D printed working electrodes with EC gold deposition. Two commercial conductive filament brands were used and investigated to fabricate electrode chips. Furthermore, strategies to apply epoxy glue and conductive silver paint were investigated to control the electrode surface area and ensure good electrical connection. This device enables detection at drinking water concentration thresholds. The practical application of the fabricated electrodes is demonstrated by detecting Cu²⁺ using anodic stripping voltammetry.

Customized electrodes were made with 3-D printing and gold electrochemical reduction towards analytical applications.