High-throughput roll-to-roll production of polymer biochips for multiplexed DNA detection in point-of-care diagnostics.

Roll-to-roll UV nanoimprint lithography has superior advantages for high-throughput manufacturing of micro- or nano-structures on flexible polymer foils with various geometries and configurations. Our pilot line provides large-scale structure imprinting for cost-effective polymer biochips (4500 biochips/hour), enabling rapid and multiplexed detections. A complete high-volume process chain of the technology for producing structures like µ-sized, triangular optical out-couplers or capillary channels (width: from 1 µm to 2 mm, height: from 200 nm up to 100 µm) to obtain biochips (width: 25 mm, length: 75 mm, height: 100 µm to 1.5 mm) was described. The imprinting process was performed with custom-developed resins on polymer foils with resin thicknesses ranging between 125-190 µm. The produced chips were tested in a commercial point-of-care diagnostic system for multiplexed DNA analysis of methicillin resistant Staphylococcus aureus (e.g., mecA, mecC gene detections). Specific target DNA capturing was based on hybridisation between surface bound DNA probes and biotinylated targets from the sample. The immobilised biotinylated targets subsequently bind streptavidin-horseradish peroxidase conjugates, which in turn generate light upon incubation with a chemiluminescent substrate. To enhance the light out-coupling thus to improve the system performance, optical structures were integrated into the design. The limits-of-detection of mecA (25 bp) for chips with and without structures were calculated as 0.06 and 0.07 µM, respectively. Further, foil-based chips with fluidic channels were DNA functionalised in our roll-to-roll micro-array spotter following the imprinting. This straightforward approach of sequential imprinting and multiplexed DNA functionalisation on a single foil was also realised for the first time. The corresponding foil-based chips were able to detect mecA gene DNA sequences down to a 0.25 µM concentration.

3D Carbon Microelectrodes with Bio-Functionalized Graphene for Electrochemical Biosensing.

An enzyme-based electrochemical biosensor has been developed with 3D pyrolytic carbon microelectrodes that have been coated with bio-functionalized reduced graphene oxide (RGO). The 3D carbon working electrode was microfabricated using the pyrolysis of photoresist precursor structures, which were subsequently functionalized with graphene oxide and enzymes. Glucose detection was used to compare the sensor performance achieved with the 3D carbon microelectrodes (3DCMEs) to the 2D electrode configuration. The 3DCMEs provided an approximately two-fold higher sensitivity of 23.56 µA·mM-1·cm-2 compared to 10.19 µA mM-1·cm-2 for 2D carbon in glucose detection using cyclic voltammetry (CV). In amperometric measurements, the sensitivity was more than 4 times higher with 0.39 µA·mM-1·cm-2 for 3D electrodes and 0.09 µA·mM-1·cm-2 for the 2D configuration. The stability analysis of the enzymes on the 3D carbon showed reproducible results over 7 days. The selectivity of the electrode was evaluated with solutions of glucose, uric acid, cholesterol and ascorbic acid, which showed a significantly higher response for glucose.