Miniaturization is the key challenge and research trend currently pursued in the field of biosensing. Moore's law, a theory in the field of microelectronics, postulated the continuous advancement of the industry by doubling the number of on-chip transistors every two years. This exponential growth in transistor count has led to a reduction in cost per function. Miniaturizing the transducer as well as the biosensing element means a boost in enhancing sensitivity and specificity features. This advancement will contribute to the achievement of three key performance metrics in biosensors: enhancing the limit of detection, reducing response time, and lowering production costs.
The kinetics of transport reactions in biosensing are closely linked to the time needed for biorecognition events to take place. In this context, the background current associated with the charging of the double layer (capacitive current) varies in proportion to the electrode's conductive area. In miniaturized electrochemical cells, the resistive drop is minimized by shortening the ionic current pathway. As a result, the capacitance is reduced, leading to a decreased time constant of the system. This enables faster electron transfer kinetics compared to macroscale systems.
The possibility to reduce dimensions brings several side advantages. Among these, first of all portability and integration into complex platform, allowing to realize multiplexed analysis, including sample treatment tools and parallelize functions. This not only enables the creation of compact yet robust devices, but also has the added benefit of reducing manufacturing costs by minimizing materials and fabrication expenses per device. This efficiency in mass production contributes to overall cost reduction.
2.2. Nanomaterials in Electrochemical Sensors Integrated in LOC Device: From 2D to 3D Electrodes
Nanomaterials have emerged as a promising class of materials for sensing applications due to their unique physicochemical properties [
41,
42,
43]. The exceptional properties exhibited by nanomaterials, including high surface area, excellent electrical and thermal conductivity, as well as unique optical characteristics, make them highly advantageous for seamless integration into lab-on-a-chip (LOC) devices as electrochemical sensors. This integration enables the detection of molecules in body fluids with significantly improved sensitivity and accuracy [
44].
Microfluidic devices offer the ability to control the flow of fluids at the microscale, enabling the rapid and precise detection of biomolecules. When combined with nanomaterial-based sensors, real-time monitoring of low concentrations of biomolecules in body fluids such as blood [
45], urine [
46], tears [
47] and saliva [
48] can be achieved. The incorporation of nanomaterials in electrochemical biosensors holds the potential to bring about a revolutionary transformation in the field of clinical diagnostics. This advancement facilitates the rapid, sensitive, and highly specific detection of biomolecules in body fluids, paving the way for significant advancements in medical diagnosis and patient care. This enhancement is achieved through either promoting electronic transfers or increasing the volume/surface area ratio [
49]. This has significant implications for medical diagnosis and treatment, as it can enable the early detection and monitoring of diseases such as cancer, diabetes, and cardiovascular diseases or timely identification of bacterial infections.
The integration of nanomaterials onto the electrode surface of microfluidic devices plays a crucial role in the advancement of high-performance electrochemical sensors. This is particularly important when electrodes are situated in less accessible locations, as often encountered in lab-on-chip systems. By incorporating nanomaterials, the sensitivity and overall performance of the electrochemical sensors can be significantly enhanced, enabling accurate and reliable detection in challenging sample environments. In this kind of device, nanomaterials are typically integrated onto the electrode surface using various techniques, such as in situ synthesis [
50], drop-casting [
51], spin-coating [
52], electrochemical deposition [
53], electrospinning [
54] and inkjet printing [
55]. Drop-casting and spin-coating are simple and cost-effective techniques that involve the deposition of nanomaterials onto the electrode surface using a dropper or a spinning device, respectively. Electrochemical deposition involves the deposition of nanomaterials onto the electrode surface by applying a voltage or a current to the electrode in the presence of the nanomaterials in solution. Inkjet printing involves the precise deposition of nanomaterials onto the electrode surface using a specialized printer. Among them, electrochemical deposition and inkjet printing are the techniques that allow for the most precise and controlled deposition of nanomaterials onto the electrode surface, which is critical for the development of high-performance electrochemical sensors.
Various types of organic and inorganic nanomaterials, including carbon nanotubes, graphene, metal and metal oxide, polymer, quantum dots, Prussian Blue [
56], nanorods, and tubes, have been incorporated into electrochemical transducers to enhance electrochemical sensing.
Figure 3.
An overview of the nanomaterials used for biosensing.
Figure 3.
An overview of the nanomaterials used for biosensing.
Metallic nanostructures, such as gold [
57], silver [
58], and platinum [
59], have been widely used in electrochemical sensors integrated into microfluidic devices for the detection of molecules in body fluids. Gold nanoparticles (AuNPs), for example, have been extensively studied due to their unique electronic, optical, and surface properties, which make them ideal for use in biosensing applications [
60]. AuNPs have been used in a variety of electrochemical sensors for the detection of different biomolecules, such as glucose, cholesterol [
61], and prostate-specific antigen (PSA) [
62] .
Magnetic nanoparticles (MNPs), such as iron oxide nanoparticles, have also been used in electrochemical biosensors integrated into microfluidic devices for the detection of biomolecules in bodily fluids. MNPs have unique magnetic and surface properties, which make them ideal for use in biosensing applications [
63]. These nanomaterials not only improve the limit of detection of the sensors, but also enable the separation and transportation of bioanalytes inside the microfluidic device, thereby allowing for the miniaturization of analytical methods [
64]. For example, MNPs functionalized with iridium oxide nanoparticles and tyrosinase have been used for the detection and quantification of methimazole in microsystems. In the analytical measurements a permanent magnet was used to immobilize the magnetic complex on the electrode surface. The system was highly sensitive with a low limit of detection (0.004 μM) and demonstrated effectiveness in serum samples. Interestingly, the use of microfluidic device allows for improve limit of detection, reusability, automation, volume of the sample, and response time compared to batch configuration [
65].
Among nonmetallic nanomaterials, carbon nanotubes (CNTs) [
66], graphene [
67], and quantum dots [
68,
69] (QDs) have shown high sensitivity towards various analytes, including glucose [
70], cholesterol [
71], and proteins, [
72] with detection limits in the sub-nanomolar range. Moreover, carbon-based nanomaterials such as graphene and carbon nanotubes have also been combined with metallic nanoparticles or polymeric layers to produce nanocomposites with improved performance [
73,
74,
75] in terms of electronic transfer or selectivity.
One of the challenges associated with the use of nanomaterials in electrochemical sensors integrated into microfluidic devices is the reproducibility and stability of the sensors. Due to the small size of nanomaterials, synthesizing and functionalizing these materials can be challenging, leading to variations in sensor performance. Additionally, the stability of nanomaterial-based sensors can be affected by factors such as temperature, pH, and humidity, resulting in reduced sensor performance over time. Efforts are being made to address these challenges, by developing reproducible synthesis and functionalization methods and optimizing sensor design to enhance stability.
Another challenge related to the use of nanomaterials in electrochemical sensors integrated into microfluidic devices is the integration of these sensors into practical clinical applications. While many studies have demonstrated the feasibility of using nanomaterial-based sensors for detecting biomolecules in body fluids, further development and optimization are required before these sensors can be widely adopted in clinical settings. This includes optimizing sensitivity, selectivity, and stability of the sensors, as well as developing user-friendly and cost-effective instrumentation for their use. In fact, despite the enhanced sensor performance offered by nanomaterials implemented on electrode surfaces, the two-dimensional planar electrodes can still limit component and signal transmission when used in vivo, thereby affecting sensor accuracy and sensitivity [
76,
77]. This limitation is particularly true for complex samples such as blood or plasma used in point-of-care-devices [
78,
79]. Furthermore, the planar structure of two-dimensional electrodes poses challenges in achieving adequate immobilization of active components and efficient signal transmission, leading to potential issues in sensing accuracy. To address these limitations, the integration of macroscale three-dimensional (3D) porous materials, comprising nanomaterials combined with polymers [
80,
81,
82,
83] can be employed as electrodes. This approach facilitates expanded microfluidic transport and enables the incorporation of multianalyte detection capabilities, thereby enhancing the overall performance of the sensor system.
The incorporation of porous channels in biosensing systems offers several advantages, including increased surface area, enhanced ion/mass transport pathways, and improved immobilization and stability of active components. In this context, graphene has emerged as a promising avenue for the development of three-dimensional (3D) electrodes. Graphene can be fabricated in the form of aerogel or combined with polymers, providing an excellent opportunity to create highly efficient and versatile 3D electrode structures. Furthermore, the surface of graphene can be easily engineered with other nanomaterials and biorecognition elements. For instance, Xu et al. [
84] demonstrated the use of a graphene foam (GF) modified with carbon-doped titanium dioxide nanofibers (nTiO2) as an electrochemical working electrode. The three-dimensional and porous structure of the GF facilitated the penetration and attachment of nTiO2 onto its surface, resulting in enhanced charge transfer resistance, increased surface area, and improved access of the analyte to the sensing surface. The GF-nTiO2 composite was further functionalized with the ErB2 antibody for specific detection of the target ErbB2 antigen, a biomarker for breast cancer. The sensor was employed for quantification of the ErbB2 antigen using differential pulse voltammetry and electrochemical impedance spectroscopy techniques. Remarkably, both methods exhibited high sensitivity across a wide concentration range of the target antigen, demonstrating excellent specificity even in the presence of other members of the EGFR family.
In another study, Zhang et al. [
85] conducted a study where they developed an enzymatic electrochemical microfluidic biosensor for glucose detection. The biosensor incorporated a three-dimensional porous graphene aerogel and glucose oxidase (GOx), taking advantage of the aerogel's high electrical conductivity and specific surface area to enhance the immobilization of GOx. The microfluidic system implemented in the biosensor reduced sample consumption during testing. The biosensor exhibited excellent selectivity and stability and successfully monitored glucose levels in serum samples. This innovative biosensor shows promise for clinical applications in diabetes diagnosis, and the method employed for preparing the graphene aerogel modified electrode holds potential for broader use in diverse electrochemical sensors.
In addition to high sensitivity, nanomaterial-based sensors are highly selective, enabling the detection of specific molecules in complex biological samples. This selectivity is achieved through the functionalization and modification of nanomaterials, by attaching specific ligands (e.g. antibodies, DNA, RNA, aptamers, and enzymes) [
86] through covalent or non-covalent interactions to enhance specificity and electronic transfer in sensors. For example, Fan et al. (2022) developed a smartphone-based electrochemical system composed of CNTs functionalized with gold nanoparticles, thionine, and antibodies for the detection of CA125, a biomarker for prostate cancer [
87]. The biosensor exhibited high selectivity towards CA125, with no interference from other biomolecules present in human serum.
Another approach to obtaining sensors with high specificity is the creation of molecular imprinted polymers (MIPs). MIPs are polymer-based artificial receptors with the ability to recognize different types of target molecules such as aminoacids, peptides [
88], pesticides [
89] and drugs [
90] but even larger molecules such as proteins [
91] or whole cells [
92]. The target molecules act as template and interact with functional monomers to form a complex during the polymerization, then the template can be removed and leaving cavities able to rebind template molecules thank to its geometry ant chemical moieties. MIPs have been largerly used as recognition elements in electrochemical sensors offering great advantages such as improved stability, cost-effectiveness and rapid fabrication procedure overcoming limitations of natural receptors (antibodies, nucleic acids, peptides) such as sensitivity to enzymatic digestion, low preservation temperature, etc.
So, combining the advantages of MIPs and electrochemical transducers several sensing platform have been realized joining sensitivity and ease to use of electrochemical sensors with high selectivity and stability of MIPs [
93]. To realize a high-performance sensing platform based on MIP as artificial receptor it is necessary to consider at least two key aspect: (i) the choice of polymer and (ii) imprinting processes. Electrochemical sensors are compatible with different imprinting approaches such as in situ bulk polymerization, surface imprinting and electrosynthesis.
The most commonly employed approach for imprinting is bulk imprinting, wherein the transducer surface is coated with a mixture of template and pre-polymer that exhibit mutual interaction. Then after polymerization template molecules are entrapped inside the polymer matrix and can be removed by a washing step creating cavities able to recognize the analyte in the subsequent analytic steps. To apply this technique to larger molecules is necessary to realize a very thin layer of polymer so the imprinted binding sites are near the interface making template removal and rebinding easier. Another possibility for the recognition of large molecules such as proteins is epitope imprinting that consists of imprinting only a portion of the target molecules [
94].
An alternative approach is based on electrosynthesis in which polymerization is induced by applying a suitable potential range to a solution containing the monomers with the template molecules without any initiator. The characteristics of resulting films can be tuned by modulating electrochemical parameters. Conductive polymers (CP) and insulators/non-conductive polymers (NCP) can be used with different advantages and disadvantages. Non-conducting MIP films self-limits their growth, so allow a fine control on their thickness, while CPs are more flexible and offer the possibility to tune not only the thickness but even the conductive properties by changing the deposition conditions. The selection of polymers is strictly related to the detection methods: for example capacitive [
95] or impedimetric [
96] sensors require nonconductive polymers, while for amperometric detection is better to use conductive ones [
97].
Surface imprinting is one of the most used technique for the development of MIPs for large molecules, cells and microorganisms: it consists in the template imprinting only on the MIP surface. Several techniques such as soft lithography, micro-contact imprinting, and sacrificial template support methods have been exploited to confine the imprinted sites on the MIP interface [
98].
The analytical performances of electrochemical MIP-based sensors can be furtherly improved by combining MIP technology with nanomaterials and realizing imprinted nanocomposite. Different nanomaterials have been used to this purpose ranging from carbon based materials (e.g. nanotubes [
99,
100], graphene [
101]) to metallic nanoparticles [
102]: this transition towards nanoMIP significantly improved the analytical performances of MIP based sensors in terms of detection limits and sensitivity and the nanostructuration of the material allows for better diffusion of the analyte on the transducer surface, resulting in a faster response time for the sensor. Nevertheless further efforts are still necessary to have standardized procedures for industrial applications and medical diagnostics.