Fully Printed Wearable Microfluidic Devices for High-Throughput Sweat Sampling and Multiplexed Electrochemical Analysis

Although the recent advancement in wearable biosensors provides continuous, noninvasive assessment of physiologically relevant chemical markers from human sweat, several bottlenecks still exist for its practical use. There were challenges in developing a multiplexed biosensing system with rapid microfluidic sampling and transport properties, as well as its integration with a portable potentiostat for improved interference-free data collection. Here, we introduce a clean-room free fabrication of wearable microfluidic sensors, using a screen-printed carbon master, for the electrochemical monitoring of sweat biomarkers during exercise activities. The sweat sampling is enhanced by introducing low-dimensional sensing compartments and lowering the hydrophilicity of channel layers via facile silane functionalization. The fluidic channel captures sweat at the inlet and directs the real-time sweat through the active sensing electrodes (within 40 s) for subsequent decoding and selective analyses. For proof of concept, simultaneous amperometric lactate and potentiometric ion sensing (Na+, K+, and pH) are carried out by a miniature circuit board capable of cross-talk-free signal collection and wireless signal transduction characteristics. All of the sensors demonstrated appreciable sensitivity, selectivity, stability, carryover efficiency, and repeatability. The floating potentiometric circuits eliminate the signal interference from the adjacent amperometric transducers. The fully integrated pumpless microfluidic device is mounted on the epidermis and employed for multiplexed real-time decoding of sweat during stationary biking. The regional variations in sweat composition are analyzed by human trials at the underarm and upperback locations. The presented method offers a large-scale fabrication of inexpensive high-throughput wearable sensors for personalized point-of-care and athletic applications.