Realizing new designs of multiplexed electrode chips by 3-D printed masks

Creating small and portable analytical methods is a fast-growing field of research. Devices capable of performing bio-analytical detection are especially desirable with the onset of the global pandemic. Lab-on-a-chip (LOC) technologies, including rapid point-of-care (POC) devices such as glucose sensors, are attractive for applications in resource-poor settings. There are many challenges in creating such devices, from sensitive molecular designs to stable conditions for storing the sensor chips. In this study we have explored using three-dimensional (3D) printing to create shadow masks as a low-cost method to produce multiplexed electrodes by physical vapour deposition. Although the dimensional resolution of the electrodes produced by using 3D printed masks is inferior to those made through photolithography-based techniques, their dimensions can be readily tailored ranging from 1 mm to 3 mm. Multiple mask materials were tested, such as polylactic acid and polyethylene terephthalate glycol, with acrylonitrile butadiene styrene shown to be the best. Simple strategies in making chip holders by 3D printing and controlling working electrode surface area with epoxy glue were also investigated. The prepared chips were tested by performing surface chemistry with thiol-containing molecules and monitoring the signals electrochemically.