3D Polymeric Lattice Microstructure-Based Microneedle Array for Transdermal Electrochemical Biosensing

Microneedles (MNs) or microneedle arrays (MNAs) are critical components of minimally invasive devices comprised of a single or a series of micro-scale projections. MNs can bypass the outermost layer of the skin and painlessly access microcirculation of the epidermis and dermis layers, attracting great interest in the development of personalized healthcare monitoring and diagnostic devices. However, MN technology has not yet reached its full potential since current micro- and nanofabrication methods do not address the need of fabricating MNs with complex surfaces to facilitate the development of clinically adequate devices. This work presents a new approach that combines 3D printing technology based on two-photon polymerization with soft lithography for cost-effective and time-saving fabrication of complex MNAs. Specifically, this method relies on printing complex 3D objects efficiently replicated into polymeric substrates via soft lithography, resulting in a free-standing polymeric lattice (PL) membrane that can be transferred onto gold-coated MNs and used for electrochemical biosensing. This platform shows excellent electrochemical performance in detecting metabolite (glucose) and protein (insulin) biomarkers with a dynamic linear range sufficient for detecting biomarkers in healthy individuals and patients. The approach holds great potential for fabricating next-generationMNs, including their transfer into clinically adequate devices.