Advancing Multi-Ion Sensing with Poly-Octylthiophene: 3D-Printed Milker-Implantable Microfluidic Device

On-site rapid multi-ion sensing accelerates early identification of environmental pollution, water quality, and disease biomarkers in both livestock and humans. This study introduces a pocket-sized 3D-printed sensor, manufactured using additive manufacturing, specifically designed for detecting iron (Fe²⁺), nitrate (NO₃ ^-), calcium (Ca²⁺), and phosphate (HPO₄ ^2-). A unique feature of this device is its utilization of a universal ion-to-electron transducing layer made from highly redox-active poly-octylthiophene (POT), enabling an all-solid-state electrode tailored to each ion of interest. Manufactured with an extrusion-based 3D printer, the device features a periodic pattern of lateral layers (width = 80 µm), including surface wrinkles. The superhydrophobic nature of the POT prevents the accumulation of nonspecific ions at the interface between the gold and POT layers, ensuring exceptional sensor selectivity. Lithography-free, 3D-printed sensors achieve sensitivity down to 1 ppm of target ions in under a minute due to their 3D-wrinkled surface geometry. Integrated seamlessly with a microfluidic system for sample temperature stabilization, the printed sensor resides within a robust, pocket-sized 3D-printed device. This innovation integrates with milking parlors for real-time calcium detection, addressing diagnostic challenges in on-site livestock health monitoring, and has the capability to monitor water quality, soil nutrients, and human diseases.