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3D-Printed Flexible Microfluidic Health Monitor for In Situ Sweat Analysis and Biomarker Detection
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    3D-Printed Flexible Microfluidic Health Monitor for In Situ Sweat Analysis and Biomarker Detection
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    • Chuchu Chen
      Chuchu Chen
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
      More by Chuchu Chen
    • Yonghao Fu
      Yonghao Fu
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
      More by Yonghao Fu
    • Sonja S. Sparks
      Sonja S. Sparks
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
    • Zhaoyuan Lyu
      Zhaoyuan Lyu
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
      More by Zhaoyuan Lyu
    • Arijit Pradhan
      Arijit Pradhan
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
    • Shichao Ding
      Shichao Ding
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
      More by Shichao Ding
    • Narasimha Boddeti
      Narasimha Boddeti
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
    • Yun Liu
      Yun Liu
      Research School of Chemistry, Australian National University, Canberra, ACT 2601, Australia
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    • Yuehe Lin
      Yuehe Lin
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
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    • Dan Du*
      Dan Du
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
      *Email: [email protected]
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    • Kaiyan Qiu*
      Kaiyan Qiu
      School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
      *Email: [email protected]
      More by Kaiyan Qiu
    Other Access OptionsSupporting Information (3)

    ACS Sensors

    Cite this: ACS Sens. 2024, 9, 6, 3212–3223
    Click to copy citationCitation copied!
    https://doi.org/10.1021/acssensors.4c00528
    Published May 31, 2024
    Copyright © 2024 American Chemical Society

    Abstract

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    Wearable sweat biosensors have shown great progress in noninvasive, in situ, and continuous health monitoring to demonstrate individuals’ physiological states. Advances in novel nanomaterials and fabrication methods promise to usher in a new era of wearable biosensors. Here, we introduce a three-dimensional (3D)-printed flexible wearable health monitor fabricated through a unique one-step continuous manufacturing process with self-supporting microfluidic channels and novel single-atom catalyst-based bioassays for measuring the sweat rate and concentration of three biomarkers. Direct ink writing is adapted to print the microfluidic device with self-supporting structures to harvest human sweat, which eliminates the need for removing sacrificial supporting materials and addresses the contamination and sweat evaporation issues associated with traditional sampling methods. Additionally, the pick-and-place strategy is employed during the printing process to accurately integrate the bioassays, improving manufacturing efficiency. A single-atom catalyst is developed and utilized in colorimetric bioassays to improve sensitivity and accuracy. A feasibility study on human skin successfully demonstrates the functionality and reliability of our health monitor, generating reliable and quantitative in situ results of sweat rate, glucose, lactate, and uric acid concentrations during physical exercise.

    Copyright © 2024 American Chemical Society

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    Supporting Information

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    The Supporting Information is available free of charge at https://pubs.acs.org/doi/10.1021/acssensors.4c00528.

    • Additional experimental details, including materials and methods; finite element analysis of the microfluidic structure; fabrication of Fe–N–C SACs through synthesis and pyrolysis at 950°C; characterization of Fe–N–C SACs; comparison of detection linear range and limit of detection (LOD) of wearable sensors for detecting biomarkers in sweat; concentrations of the biomarker corresponding to the R values (PDF)

    • 3D-printing process for the health monitor (Movie S1) (MP4)

    • Experimental setup for testing of the microfluidic channel (Movie S2) (MP4)

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    This article is cited by 9 publications.

    1. Alana F. Ogata, Julia Kramer. A Patient-Centered Approach in Sensor Science: Embracing Patient Engagement for Translational Clinical Technologies. ACS Sensors 2025, Article ASAP.
    2. J. Justin Gooding (Editor-in-Chief). Some of Our Favorite Papers from the First 10 Years of ACS Sensors. ACS Sensors 2025, 10 (1) , 1-3. https://doi.org/10.1021/acssensors.4c03746
    3. Pengxin Xue, Shaokun Zhou, Guanglei Li, Dan Wen. Functional design of metal aerogels for wearable electrochemical biosensing devices. Chemical Communications 2025, 61 (25) , 4774-4783. https://doi.org/10.1039/D4CC06728B
    4. Haiyan Wang, Wenjuan Wu. Recent Advancements in Microfluidic Biosensors for Clinical Applications. iLABMED 2025, https://doi.org/10.1002/ila2.70002
    5. Yiyue Tao, Tangzhen Guan, Yibing Ma, Guanghao Sang, Jing Liu. Stretchable soft batteries: From structures to materials. Energy Storage Materials 2025, 76 , 104085. https://doi.org/10.1016/j.ensm.2025.104085
    6. Chuchu Chen, Yonghao Fu, Yun Liu, Prashanta Dutta, Yuehe Lin, Dan Du, Kaiyan Qiu. Next-generation health monitoring: The role of nanomaterials in 3D-printed wearable devices. Materials Today 2025, 18 https://doi.org/10.1016/j.mattod.2025.03.005
    7. Yingcong Zhang, Yiran Yang, Zhixin Yin, Lin Huang, Jiayi Wang. Nanozyme-based wearable biosensors for application in healthcare. iScience 2025, 28 (2) , 111763. https://doi.org/10.1016/j.isci.2025.111763
    8. Md Abu Zahed, S M Sohel Rana, Omar Faruk, M. Robiul Islam, Md Selim Reza, YeYeong Lee, Gagan Bahadur Pradhan, Md Asaduzzaman, Dongyun Kim, Trilochan Bhatta, Jae Yeong Park. Self‐Powered Wireless System for Monitoring Sweat Electrolytes in Personalized Healthcare Wearables. Advanced Functional Materials 2024, 13 https://doi.org/10.1002/adfm.202421021
    9. Sonja S. Sparks, Alejandro G. Obando, Yizong Li, Si Chen, Shanshan Yao, Kaiyan Qiu. 3D‐printed biomimetic and bioinspired soft actuators. IET Cyber-Systems and Robotics 2024, 6 (4) https://doi.org/10.1049/csy2.70001

    ACS Sensors

    Cite this: ACS Sens. 2024, 9, 6, 3212–3223
    Click to copy citationCitation copied!
    https://doi.org/10.1021/acssensors.4c00528
    Published May 31, 2024
    Copyright © 2024 American Chemical Society

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