Hybrid Printing of Fully Integrated Microfluidic Devices for Biosensing

Abstract The advent of 3D printing has facilitated the rapid fabrication of microfluidic devices that are accessible and cost‐effective. However, it remains a challenge to fabricate sophisticated microfluidic devices with integrated structural and functional components due to limited material options of existing printing methods and their stringent requirement on feedstock material properties. Here, a multi‐materials multi‐scale hybrid printing method that enables seamless integration of a broad range of structural and functional materials into complex devices is reported. A fully printed and assembly‐free microfluidic biosensor with embedded fluidic channels and functionalized electrodes at sub‐100 µm spatial resolution for the amperometric sensing of lactate in sweat is demonstrated. The sensors present a sensitive response with a limit of detection of 442 nm and a linear dynamic range of 1–10 mm, which are performance characteristics relevant to physiological levels of lactate in sweat. The versatile hybrid printing method offers a new pathway toward facile fabrication of next‐generation integrated devices for broad applications in point‐of‐care health monitoring and sensing.