Surface-enhanced Raman spectroscopy (SERS) combines the high speciﬁcity of Raman scattering with high sensitivity due to an enhancement of the electromagnetic ﬁeld by metallic nanostructures. However, the tyical fabrication methods of SERS substrates suffer from low throughput and therefore high costs. Furthermore, point-of-care applications require the investigation of liquid solutions and thus the integration of the SERS substrate in a microfluidic chip. We present a roll-to-roll fabrication approach for microfluidics with integrated, highly efficient, surface-enhanced Raman scattering structures. Microfluidic channels are formed using roll-to-roll hot embossing in polystyrene foil. Aerosol jet printing of a gold nanoparticle ink is utilized to manufacture highly efficient, homogeneous, and reproducible SERS structures. The modified channels are sealed with a solvent-free, roll-to-roll, thermal bonding process. In continuous flow measurements, these chips overcome time-consuming incubation protocols and the poor reproducibility of SERS experiments often caused by inhomogeneous drying of the analyte. In the present study, we explore the influence of the printing process on the homogeneity and the enhancement of the SERS structures. The feasibility of aerosol-jet-modified microfluidic channels for highly sensitive SERS detection is demonstrated by using solutions with different concentrations of Rhodamine 6G and adenosine. The printed areas provide homogeneous enhancement factors of ~4 × 106
. Our work shows a way towards the low-cost production of tailor-made, SERS-enabled, label-free, lab-on- chip systems for bioanalysis.
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