Comparison of Ultrasonic Welding and Thermal Bonding for the Integration of Thin Film Metal Electrodes in Injection Molded Polymeric Lab-on-Chip Systems for Electrochemistry

Extraction, Enrichment, and in situ Electrochemical Detection on Lab-on-a-Disc: Monitoring the Production of a Bacterial Secondary Metabolite

Development of microsystems, which enable "sample-to-answer" detection from real samples, is often challenging. We present the first integration of supported liquid membrane extraction combined with electrochemical detection on a centrifugal fluidic platform. The developed lab-on-a-disc (LoD) system enabled the separation, enrichment, and subsequent electrochemical detection of the target analyte from a complex sample mixture. As a case study, we quantified the amount of a dietary supplement and pharmaceutical precursor, p-coumaric acid, from bacterial growth media at different time points during production. The assay, extraction, and detection, performed on the LoD device, proved to be a low cost and environmentally friendly approach, requiring only a few tens of microliters of organic solvent and enabled detection in a 3 μL volume. In addition, the data obtained from the centrifugal platform showed a good correlation with data obtained from the high performance liquid chromatography analysis.

Injection-Molded Microfluidic Device for SERS Sensing Using Embedded Au-Capped Polymer Nanocones

To enable affordable detection and diagnostic, there is a need for low-cost and mass producible miniaturized sensing platforms. We present a fully polymeric microfluidic lab-on-a-chip device with integrated gold (Au)-capped nanocones for sensing applications based on surface-enhanced Raman spectroscopy (SERS). All base components of the device were fabricated via injection molding (IM) and can be easily integrated using ultrasonic welding. The SERS sensor array, embedded in the bottom of a fluidic channel, was created by evaporating Au onto IM nanocone structures, resulting in densely packed Au-capped SERS active nanostructures. Using a Raman active model analyte, trans-1,2-bis-(4-pyridyl)-ethylene, we found a surface-averaged SERS enhancement factor of ∼5 × 10⁶ with a relative standard deviation of 14% over the sensor area (2 × 2 mm²), and a 18% signal variation among substrates. This reproducible fabrication method is cost-effective, less time consuming, and allows mass production of fully integrated polymeric, microfluidic systems with embedded high-density and high-aspect ratio SERS sensor.

Recent Advancements towards Full-System Microfluidics

Microfluidics is quickly becoming a key technology in an expanding range of fields, such as medical sciences, biosensing, bioactuation, chemical synthesis, and more. This is helping its transformation from a promising R&D tool to commercially viable technology. Fuelling this expansion is the intensified focus on automation and enhanced functionality through integration of complex electrical control, mechanical properties, in situ sensing and flow control. Here we highlight recent contributions to the Sensors Special Issue series called "Microfluidics-Based Microsystem Integration Research" under the following categories: (i) Device fabrication to support complex functionality; (ii) New methods for flow control and mixing; (iii) Towards routine analysis and point of care applications; (iv) In situ characterization; and (v) Plug and play microfluidics.

Electrokinetic Phenomena in Pencil Lead-Based Microfluidics

Fabrication of microchannels and associated electrodes to generate electrokinetic phenomena often involves costly materials and considerable effort. In this study, we used graphite pencil-leads as low cost, disposable 3D electrodes to investigate various electrokinetic phenomena in straight cylindrical microchannels, which were themselves fabricated by using a graphite rod as the microchannel mold. Individual pencil-leads were employed as the micro-electrodes arranged along the side walls of the microchannel. Efficient electrokinetic phenomena provided by the 3D electrodes, including alternating current electroosmosis (ACEO), induced-charge electroosmosis (ICEO), and dielectrophoresis (DEP), were demonstrated by the introduced pencil-lead based microfluidic devices. The electrokinetic phenomena were characterized by micro-particle image velocimetry (micro-PIV) measurements and microscopy imaging. Highly efficient electrokinetic phenomena using 3D pencil-lead electrodes showed the affordability and ease of this technique to fabricate microfluidic devices embedded with electrodes for electrokinetic fluid and particle manipulations.