Recent Progress in 3D Printed Mold-Based Sensors

Human Activity Recording Based on Skin-Strain-Actuated Microfluidic Pumping in Asymmetrically Designed Micro-Channels

The capability to record data in passive, image-based wearable sensors can simplify data readouts and eliminate the requirement for the integration of electronic components on the skin. Here, we developed a skin-strain-actuated microfluidic pump (SAMP) that utilizes asymmetric aspect ratio channels for the recording of human activity in the fluidic domain. An analytical model describing the SAMP's operation mechanism as a wearable microfluidic device was established. Fabrication of the SAMP was achieved using soft lithography from polydimethylsiloxane (PDMS). Benchtop experimental results and theoretical predictions were shown to be in good agreement. The SAMP was mounted on human skin and experiments conducted on volunteer subjects demonstrated the SAMP's capability to record human activity for hundreds of cycles in the fluidic domain through the observation of a stable liquid meniscus. Proof-of-concept experiments further revealed that the SAMP could quantify a single wrist activity repetition or distinguish between three different shoulder activities.

Mold-Free Manufacturing of Highly Sensitive and Fast-Response Pressure Sensors Through High-Resolution 3D Printing and Conformal Oxidative Chemical Vapor Deposition Polymers

A new manufacturing paradigm is showcased to exclude conventional mold-dependent manufacturing of pressure sensors, which typically requires a series of complex and expensive patterning processes. This mold-free manufacturing leverages high-resolution 3D-printed multiscale microstructures as the substrate and a gas-phase conformal polymer coating technique to complete the mold-free sensing platform. The array of dome and spike structures with a controlled spike density of a 3D-printed substrate ensures a large contact surface with pressures applied and extended linearity in a wider pressure range. For uniform coating of sensing elements on the microstructured surface, oxidative chemical vapor deposition is employed to deposit a highly conformal and conductive sensing element, poly(3,4-ethylenedioxythiophene) at low temperatures (<60 °C). The fabricated pressure sensor reacts sensitively to various ranges of pressures (up to 185 kPa-1 ) depending on the density of the multiscale features and shows an ultrafast response time (≈36 µs). The mechanism investigations through the finite element analysis identify the effect of the multiscale structure on the figure-of-merit sensing performance. These unique findings are expected to be of significant relevance to technology that requires higher sensing capability, scalability, and facile adjustment of a sensor geometry in a cost-effective manufacturing manner.

A Non-Sacrificial 3D Printing Process for Fabricating Integrated Micro/Mesoscale Molds

Three-dimensional printing technology has been implemented in microfluidic mold fabrication due to its freedom of design, speed, and low-cost fabrication. To facilitate mold fabrication processes and avoid the complexities of the soft lithography technique, we offer a non-sacrificial approach to fabricate microscale features along with mesoscale features using Stereolithography (SLA) printers to assemble a modular microfluidic mold. This helps with addressing an existing limitation with fabricating complex and time-consuming micro/mesoscale devices. The process flow, optimization of print time and feature resolution, alignments of modular devices, and the advantages and limitations with the offered technique are discussed in this paper.

3D printing of flexible strain sensor based on MWCNTs/flexible resin composite

The flexible strain sensor is an indispensable part in flexible integrated electronic systems and an important intermediate in external mechanical signal acquisition. The 3D printing technology provides a fast and cheap way to manufacture flexible strain sensors. In this paper, a MWCNTs/flexible resin composite for photocuring 3D printing was prepared using mechanical mixing method. The composite has a low percolation threshold (1.2%ωt). Based on the composite material, a flexible strain sensor with high performance was fabricated using digital light processing technology. The sensor has a GF of 8.98 under strain conditions ranging between 0% and 40% and a high elongation at break (48%). The sensor presents mechanical hysteresis under cyclic loading. With the increase of the strain amplitude, the mechanical hysteresis becomes more obvious. At the same time, the resistance response signal of the sensor shows double peaks during the unloading process, which is caused by the competition of disconnection and reconstruction of conductive network in the composite material. The test results show that the sensor has different response signals to different types of loads. Finally, its practicability is verified by applying it to balloon pressure detection.

Wearable Sensors for Healthcare: Fabrication to Application

This paper presents a substantial review of the deployment of wearable sensors for healthcare applications. Wearable sensors hold a pivotal position in the microelectronics industry due to their role in monitoring physiological movements and signals. Sensors designed and developed using a wide range of fabrication techniques have been integrated with communication modules for transceiving signals. This paper highlights the entire chronology of wearable sensors in the biomedical sector, starting from their fabrication in a controlled environment to their integration with signal-conditioning circuits for application purposes. It also highlights sensing products that are currently available on the market for a comparative study of their performances. The conjugation of the sensing prototypes with the Internet of Things (IoT) for forming fully functioning sensorized systems is also shown here. Finally, some of the challenges existing within the current wearable systems are shown, along with possible remedies.

Review on Microscale Sensors with 3D Engineered Structures: Fabrication and Applications

The intelligence of modern technologies relies on perceptual systems based on microscale sensors. However, because of the traditional top-down fabrication approaches performed on planar silicon wafers, a large proportion of existing microscale sensors have 2D structures, which severely restricts their sensing capabilities. To overcome these restrictions, over the past few decades, increasing efforts have been devoted to developing new fabrication methods for microscale sensors with 3D engineered structures, from bulk chemical etching and 3D printing to molding and stress-induced assembly. Herein, the authors systematically review these fabrication methods based on the applications of the resulting 3D sensors and discuss their advantages compared to their 2D counterparts. This is followed by a perspective on the remaining challenges and possible opportunities.

Integration of Different Graphene Nanostructures with PDMS to Form Wearable Sensors

This paper presents a substantial review of the fabrication and implementation of graphene-PDMS-based composites for wearable sensing applications. Graphene is a pivotal nanomaterial which is increasingly being used to develop multifunctional sensors due to their enhanced electrical, mechanical, and thermal characteristics. It has been able to generate devices with excellent performances in terms of sensitivity and longevity. Among the polymers, polydimethylsiloxane (PDMS) has been one of the most common ones that has been used in biomedical applications. Certain attributes, such as biocompatibility and the hydrophobic nature of PDMS, have led the researchers to conjugate it in graphene sensors as substrates or a polymer matrix. The use of these graphene/PDMS-based sensors for wearable sensing applications has been highlighted here. Different kinds of electrochemical and strain-sensing applications have been carried out to detect the physiological signals and parameters of the human body. These prototypes have been classified based on the physical nature of graphene used to formulate the sensors. Finally, the current challenges and future perspectives of these graphene/PDMS-based wearable sensors are explained in the final part of the paper.

Recent Progress in Intelligent Wearable Sensors for Health Monitoring and Wound Healing Based on Biofluids

The intelligent wearable sensors promote the transformation of the health care from a traditional hospital-centered model to a personal portable device-centered model. There is an urgent need of real-time, multi-functional, and personalized monitoring of various biochemical target substances and signals based on the intelligent wearable sensors for health monitoring, especially wound healing. Under this background, this review article first reviews the outstanding progress in the development of intelligent, wearable sensors designed for continuous, real-time analysis, and monitoring of sweat, blood, interstitial fluid, tears, wound fluid, etc. Second, this paper reports the advanced status of intelligent wound monitoring sensors designed for wound diagnosis and treatment. The paper highlights some smart sensors to monitor target analytes in various wounds. Finally, this paper makes conservative recommendations regarding future development of intelligent wearable sensors.

Fabrication and Analysis of Polydimethylsiloxane (PDMS) Microchannels for Biomedical Application

In this research work, Polydimethylsiloxane (PDMS) has been used for the fabrication of microchannels for biomedical application. Under the internet of things (IoT)-based controlled environment, the authors have simulated and fabricated bio-endurable, biocompatible and bioengineered PDMS-based microchannels for varicose veins implantation exclusively to avoid tissue damaging. Five curved ascending curvilinear micro-channel (5CACMC) and five curved descending curvilinear micro-channels (5CDCMC) are simulated by MATLAB (The Math-Works, Natick, MA, USA) and ANSYS (ANSYS, The University of Lahore, Pakistan) with actual environments and confirmed experimentally. The total length of each channel is 1.6 cm. The diameter of both channels is 400 µm. In the ascending channel, the first to fifth curve cycles have the radii of 2.5 mm, 5 mm, 7.5 mm, 10 mm, and 2.5 mm respectively. In the descending channel, the first and second curve cycles have the radii of 12.5 mm and 10 mm respectively. The third to fifth cycles have the radii of 7.5 mm, 5 mm, and 2.5 mm respectively. For 5CACMC, at Reynolds number of 185, the values of the flow rates, velocities and pressure drops are 19.7 µLs−1, 0.105 mm/s and 1.18 Pa for Fuzzy simulation, 19.3 µLs−1, 0.1543 mm/s and 1.6 Pa for ANSYS simulation and 18.23 µLs−1, 0.1332 mm/s and 1.5 Pa in the experiment. For 5CDCMC, at Reynolds number 143, the values of the flow rates, velocities and pressure drops are 15.4 µLs−1, 0.1032 mm/s and 1.15 Pa for Fuzzy simulation, 15.0 µLs−1, 0.120 mm/s and 1.22 Pa for ANSYS simulation and 14.08 µLs−1, 0.105 mm/s and 1.18 Pa in the experiment. Both channels have three inputs and one output. In order to observe Dean Flow, Dean numbers are also calculated. Therefore, both PDMS channels can be implanted in place of varicose veins to have natural blood flow.

Recent Progress in Wearable Biosensors: From Healthcare Monitoring to Sports Analytics

Recent advances in lab-on-a-chip technology establish solid foundations for wearable biosensors. These newly emerging wearable biosensors are capable of non-invasive, continuous monitoring by miniaturization of electronics and integration with microfluidics. The advent of flexible electronics, biochemical sensors, soft microfluidics, and pain-free microneedles have created new generations of wearable biosensors that explore brand-new avenues to interface with the human epidermis for monitoring physiological status. However, these devices are relatively underexplored for sports monitoring and analytics, which may be largely facilitated by the recent emergence of wearable biosensors characterized by real-time, non-invasive, and non-irritating sensing capacities. Here, we present a systematic review of wearable biosensing technologies with a focus on materials and fabrication strategies, sampling modalities, sensing modalities, as well as key analytes and wearable biosensing platforms for healthcare and sports monitoring with an emphasis on sweat and interstitial fluid biosensing. This review concludes with a summary of unresolved challenges and opportunities for future researchers interested in these technologies. With an in-depth understanding of the state-of-the-art wearable biosensing technologies, wearable biosensors for sports analytics would have a significant impact on the rapidly growing field-microfluidics for biosensing.

3D-Printable Carbon Nanotubes-Based Composite for Flexible Piezoresistive Sensors

The intersection between nanoscience and additive manufacturing technology has resulted in a new field of printable and flexible electronics. This interesting area of research tackles the challenges in the development of novel materials and fabrication techniques towards a wider range and improved design of flexible electronic devices. This work presents the fabrication of a cost-effective and facile flexible piezoresistive pressure sensor using a 3D-printable carbon nanotube-based nanocomposite. The carbon nanotubes used for the development of the material are multi-walled carbon nanotubes (MWCNT) dispersed in polydimethylsiloxane (PDMS) prepolymer. The sensor was fabricated using the direct ink writing (DIW) technique (also referred to as robocasting). The MWCNT-PDMS composite was directly printed onto the polydimethylsiloxane substrate. The sensor response was then examined based on the resistance change to the applied load. The sensor exhibited high sensitivity (6.3 Ω/kPa) over a wide range of applied pressure (up to 1132 kPa); the highest observed measurement range for MWCNT-PDMS composite in previous work was 40 kPa. The formulated MWCNT-PDMS composite was also printed into high-resolution 3-dimensional shapes which maintained their form even after heat treatment process. The possibility to use 3D printing in the fabrication of flexible sensors allows design freedom and flexibility, and structural complexity with wide applications in wearable or implantable electronics for sport, automotive and biomedical fields.

Multivariate Design of 3D Printed Immediate-Release Tablets with Liquid Crystal-Forming Drug-Itraconazole

The simplicity of object shape and composition modification make additive manufacturing a great option for customized dosage form production. To achieve this goal, the correlation between structural and functional attributes of the printed objects needs to be analyzed. So far, it has not been deeply investigated in 3D printing-related papers. The aim of our study was to modify the functionalities of printed tablets containing liquid crystal-forming drug itraconazole by introducing polyvinylpyrrolidone-based polymers into the filament-forming matrices composed predominantly of poly(vinyl alcohol). The effect of the molecular reorganization of the drug and improved tablets’ disintegration was analyzed in terms of itraconazole dissolution. Micro-computed tomography was applied to analyze how the design of a printed object (in this case, a degree of an infill) affects its reproducibility during printing. It was also used to analyze the structure of the printed dosage forms. The results indicated that the improved disintegration obtained due to the use of Kollidon^®CL-M was more beneficial for the dissolution of itraconazole than the molecular rearrangement and liquid crystal phase transitions. The lower infill density favored faster dissolution of the drug from printed tablets. However, it negatively affected the reproducibility of the 3D printed object.

3D printing in analytical chemistry: current state and future

The rapid development of additive technologies in recent years is accompanied by their intensive introduction into various fields of science and related technologies, including analytical chemistry. The use of 3D printing in analytical instrumentation, in particular, for making prototypes of new equipment and manufacturing parts having complex internal spatial configuration, has been proved as exceptionally effective. Additional opportunities for the widespread introduction of 3D printing technologies are associated with the development of new optically transparent, current- and thermo-conductive materials, various composite materials with desired properties, as well as possibilities for printing with the simultaneous combination of several materials in one product. This review will focus on the application of 3D printing for production of new advanced analytical devices, such as compact chromatographic columns for high performance liquid chromatography, flow reactors and flow cells for detectors, devices for passive concentration of toxic compounds and various integrated devices that allow significant improvements in chemical analysis. A special attention is paid to the complexity and functionality of 3D-printed devices.