Challenges faced with 3D-printed electrochemical sensors in analytical applications

• Published in: Analytical and bioanalytical chemistry 2024-09, Vol.416 (21), p.4679-4690
• Main Authors: Pradela‑Filho, Lauro A., Araújo, Diele A. G., Ataide, Vanessa N., Meloni, Gabriel N., Paixão, Thiago R. L. C.
• Format: Article
• Language: English
• Subjects: 3-D printers; Analytical Chemistry; Biochemistry; Characterization and Evaluation of Materials; Chemical sensors; Chemistry; Chemistry and Materials Science; Critical Review; Electrochemistry; Emerging Trends in Electrochemical Analysis; Fabrication; Food Science; Fused deposition modeling; Laboratories; Laboratory Medicine; Monitoring/Environmental Analysis; Prototyping; Reference materials; Sensors; Software; Three dimensional analysis; Three dimensional printing
• ISSN: 1618-2642; 1618-2650; 1618-2650
• DOI: 10.1007/s00216-024-05308-7

Prototyping analytical devices with three-dimensional (3D) printing techniques is becoming common in research laboratories. The attractiveness is associated with printers’ price reduction and the possibility of creating customized objects that could form complete analytical systems. Even though 3D printing enables the rapid fabrication of electrochemical sensors, its wider adoption by research laboratories is hindered by the lack of reference material and the high “entry barrier” to the field, manifested by the need to learn how to use 3D design software and operate the printers. This review article provides insights into fused deposition modeling 3D printing, discussing key challenges in producing electrochemical sensors using currently available extrusion tools, which include desktop 3D printers and 3D printing pens. Further, we discuss the electrode processing steps, including designing, printing conditions, and post-treatment steps. Finally, this work shed some light on the current applications of such electrochemical devices that can be a reference material for new research involving 3D printing. Graphical Abstract