Laser material processing for design and fabrication of wearable biosensors and bioelectronics

Wearable biosensors and bioelectronics are considered some of the most crucial technologies for the continuous and real-time monitoring of physiological health, clinical diagnosis, and disease biomarkers, offering effective early-stage prevention of human health problems. However, the development and fabrication of these devices have encountered significant challenges owing to the inherent constraints, low efficiency, and limited performance of conventional technologies in preparing, depositing, and stabilizing materials on supporting substrates. Laser material processing (LMP) has emerged as a promising alternative to traditional methods for effectively patterning flexible and stretchable electrodes in biosensors and bioelectronics. This method leverages the unique properties of lasers to enable highly precise, customizable, and rapid prototyping, as well as the versatile construction of novel material structures with outstanding features. By heating or cross-linking the target materials, LMP can be effectively applied to various materials, facilitating the fabrication of compact and multifunctional wearable biosensors through a non-contact, high throughput process. This review consolidates existing scientific evidence on recent advances, development trends, and the applicability of LMP in fabricating wearable biosensors and bioelectronics. It provides a comprehensive overview of the remarkable features, advantages, and underlying principles of LMP, while also addressing the challenges and limitations involved in constructing these wearable devices-ultimately aiming to drive innovation in future research. Additionally, the latest advancements in the use of LMP for fabricating flexible and wearable electrodes with promising materials for high-performance wearable biosensors are also discussed, offering insights into potential future directions.