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

Rajendran Vinoth1,2, Tatsuo Nakagawa3, Jayaraman Mathiyarasu1,2

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Summary

This study presents a novel, low-cost wearable biosensor for real-time sweat analysis during exercise. The device enables multiplexed electrochemical monitoring of key biomarkers, enhancing personalized health and athletic performance tracking.

Keywords:
fitness monitoringmicrofluidic patchscreen printingsweat sensorwearable electronics

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Area of Science:

  • Biomedical Engineering
  • Analytical Chemistry
  • Materials Science

Background:

  • Wearable biosensors offer continuous, noninvasive sweat analysis but face challenges in multiplexing, rapid sampling, and interference-free data collection.
  • Existing systems struggle with integrating microfluidics and portable electronics for practical, real-time monitoring of physiological markers.

Purpose of the Study:

  • To develop a clean-room-free fabricated wearable microfluidic sensor for electrochemical monitoring of sweat biomarkers during exercise.
  • To enhance sweat sampling and transport properties for rapid, multiplexed analysis.
  • To integrate the sensor with a portable potentiostat for interference-free data collection and wireless signal transduction.

Main Methods:

  • Utilized screen-printed carbon master for clean-room-free fabrication of wearable microfluidic sensors.
  • Incorporated low-dimensional sensing compartments and silane functionalization to improve sweat sampling and reduce hydrophilicity.
  • Developed a miniature circuit board for simultaneous amperometric lactate and potentiometric ion (Na+, K+, pH) sensing with cross-talk-free signal collection.
  • Mounted the integrated, pumpless microfluidic device on the epidermis for real-time sweat analysis during stationary biking.

Main Results:

  • Achieved rapid (within 40 s) real-time sweat transport through the microfluidic channel to active sensing electrodes.
  • Demonstrated simultaneous sensing of lactate, Na+, K+, and pH with high sensitivity, selectivity, stability, and repeatability.
  • Verified that floating potentiometric circuits effectively eliminate signal interference from adjacent amperometric transducers.
  • Successfully analyzed regional variations in sweat composition by comparing underarm and upper back measurements during exercise.

Conclusions:

  • The developed wearable microfluidic sensor enables large-scale, inexpensive, high-throughput fabrication for personalized point-of-care and athletic applications.
  • The clean-room-free approach and integrated design overcome previous bottlenecks in wearable sweat biosensing.
  • This technology facilitates multiplexed, real-time decoding of sweat biomarkers, offering valuable insights into physiological status during physical activity.