Reproducible and Scalable Generation of Multilayer Nanocomposite Constructs for Ultrasensitive Nanobiosensing

Abstract Electrochemical nanobiosensors are ultrasensitive tools used for detection and monitoring of various markers in biofluids. In the absence of reliable techniques for large‐scale production of reproducible nanomaterial structures on the electrodes, they are created individually in batch‐production. This has become a substantial hurdle in the practical implementation of electrochemical nanobiosensors. An automated microfluidic‐based platform (NanoChip) is presented for reproducible and scalable formation of complex nanomaterial constructs with a defined order of nanocomposites and biomaterials to create ultrasensitive nanobiosensors. The automated liquid handling system of the setup delivers reagents to electrodes inserted temporarily into the chip for modifying their surfaces by depositing different nanomaterials. The NanoChip platform is used for the creation of a multilayer nanocomposite structure on the electrode surface. These reproducible nanobiosensors are used for detecting breast cancer cells in the blood. The nanobiosensors offered a dynamic detection range of 10 to 5 × 10⁶ cells mL⁻¹. Performance of sensors produced from NanoChip shows similar selectivity and operational range along with improved sensitivity and reproducibility compared to sensors developed using batch process. These features make automated Nanochip technology a versatile tool for producing nanosensors for the ultrasensitive detection of various markers in biomedical, clinical, energy, and environmental applications.