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Keywords = optical 3D µ-printing

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23 pages, 4890 KB  
Article
DUNI: A Portable Smartphone-Coupled Integrating Sphere for Controlled Illumination and Reliable Colorimetric Sensing: Analytical Applications
by Pablo Cebrián, José Manuel Escuín, Jesús Salafranca, Carmen Jarne, Ángel López-Molinero, Susana de Marcos, Javier Galbán and Isabel Sanz-Vicente
Sensors 2026, 26(11), 3329; https://doi.org/10.3390/s26113329 - 24 May 2026
Viewed by 565
Abstract
The use of smartphones as analytical instruments is becoming increasingly widespread due to their ease of use and low cost. However, it has limitations, such as dependence on the smartphone’s sensor, the light source and the environment, which hinders the reproducibility and comparability [...] Read more.
The use of smartphones as analytical instruments is becoming increasingly widespread due to their ease of use and low cost. However, it has limitations, such as dependence on the smartphone’s sensor, the light source and the environment, which hinders the reproducibility and comparability of results. This paper presents the development of a portable device, called DUNI, which can be attached to any smartphone and is designed to overcome these limitations. The device, manufactured using 3D printing and with an average cost of €35, consists of an integrating sphere, which incorporates a lighting-electronic system, as well as accessories for measuring on different surfaces. It has been optimised by evaluating the influence of the optical geometry, the size and reflective coating of the sphere, the lighting conditions, and the electronic stability on measurement performance. It has been applied to the determination of hydrogen peroxide and biogenic amines in synthetic samples, achieving relative errors of less than 5% and detection limits between 3 and 6 µM. Overall, the device we have developed constitutes a portable, versatile and low-cost platform that enables quantitative colorimetric measurements using smartphones under controlled lighting conditions, with potential applications in on-site analysis and resource-limited settings. Full article
(This article belongs to the Section Sensors Development)
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23 pages, 5718 KB  
Article
3D-Printed Microfluidic Chip System with Integrated Fluidic Breakers and Phaseguide Fluid Structures for Optimal Passive Mixing
by Christian Neubert, Tim Brauckhoff, Frank T. Hufert, Manfred Weidmann and Gregory Dame
Micromachines 2026, 17(2), 193; https://doi.org/10.3390/mi17020193 - 31 Jan 2026
Viewed by 814
Abstract
3D printing offers great potential for rapid and cost-effective fabrication of microfluidic lab-on-a-chip systems. Through a comparative approach, we implemented staggered herringbone mixer (SHM), Tesla mixer, and split and recombine mixer (SAR), along with a basic unperturbed channel into one chip and performed [...] Read more.
3D printing offers great potential for rapid and cost-effective fabrication of microfluidic lab-on-a-chip systems. Through a comparative approach, we implemented staggered herringbone mixer (SHM), Tesla mixer, and split and recombine mixer (SAR), along with a basic unperturbed channel into one chip and performed comparative mixing efficiency experiments. We also introduced a phaseguide-based, T-shaped stop structure at the Y-shaped inlets for bubble-free and parallel filling. The structures were analyzed with two poorly mixable dye solutions at flow rates ranging from 1 µL/min to 200 µL/min. The mixing efficiency was evaluated using optical gray value analysis and compared against diffusion-based mixing. The fluid-aligning phaseguides in the 3D-printed system were shown to work. Among the three different mixing structures tested, SHM exhibited the best mixing efficiency at all tested flow rates. Uniformly designed SHM structures contain a region of poor mixing between the two zones of turbulence. In a non-uniform design, fluid breakers were placed between two SHM units to redirect poorly mixed fluids to the edges, resulting in 100% mixing efficiency across all measured flow rates. These results, especially SHM with fluid breakers, support the development of cost-effective injection-molded lab-on-a-chip systems with improved mixing functionalities at close range instead of simple long-length meandric systems. Full article
(This article belongs to the Special Issue Microfluidics in Biomedical Research)
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30 pages, 1982 KB  
Perspective
Microfluidic Paper-Based Devices at the Edge of Real Samples: Fabrication Limits, Hybrid Detection, and Perspectives
by Hsing-Meng Wang, Sheng-Zhuo Lee and Lung-Ming Fu
Micromachines 2026, 17(1), 105; https://doi.org/10.3390/mi17010105 - 13 Jan 2026
Cited by 4 | Viewed by 1265
Abstract
Microfluidic paper-based analytical devices (µPADs) convert ordinary cellulose into an active analytical platform where capillary gradients shape transport, surface chemistry guides recognition, and embedded electrodes or optical probes translate biochemical events into readable signals. Progress in fabrication—from wax and stencil barriers to laser-defined [...] Read more.
Microfluidic paper-based analytical devices (µPADs) convert ordinary cellulose into an active analytical platform where capillary gradients shape transport, surface chemistry guides recognition, and embedded electrodes or optical probes translate biochemical events into readable signals. Progress in fabrication—from wax and stencil barriers to laser-defined grooves, inkjet-printed conductive lattices, and 3D-structured multilayers—has expanded reaction capacity while preserving portability. Detection strategies span colorimetric fields that respond within porous fibers, fluorescence and ratiometric architectures tuned for low abundance biomarkers, and electrochemical interfaces resilient to turbidity, salinity, and biological noise. Applications now include diagnosing human body fluids, checking food safety, monitoring the environment, and testing for pesticides and illegal drugs, often in places with limited resources. Researchers are now using learning algorithms to read minute gradients or currents imperceptible to the human eye, effectively enhancing and assisting the measurement process. This perspective article focuses on the newest advancements in the design, fabrication, material selection, testing methods, and applications of µPADs, and it explains how they work, where they can be used, and what their future might hold. Full article
(This article belongs to the Special Issue Microfluidics in Biomedical Research)
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25 pages, 9045 KB  
Article
Deep Learning-Enhanced Portable Chemiluminescence Biosensor: 3D-Printed, Smartphone-Integrated Platform for Glucose Detection
by Chirag M. Singhal, Vani Kaushik, Abhijeet Awasthi, Jitendra B. Zalke, Sangeeta Palekar, Prakash Rewatkar, Sanjeet Kumar Srivastava, Madhusudan B. Kulkarni and Manish L. Bhaiyya
Bioengineering 2025, 12(2), 119; https://doi.org/10.3390/bioengineering12020119 - 27 Jan 2025
Cited by 34 | Viewed by 4627
Abstract
A novel, portable chemiluminescence (CL) sensing platform powered by deep learning and smartphone integration has been developed for cost-effective and selective glucose detection. This platform features low-cost, wax-printed micro-pads (WPµ-pads) on paper-based substrates used to construct a miniaturized CL sensor. A 3D-printed black [...] Read more.
A novel, portable chemiluminescence (CL) sensing platform powered by deep learning and smartphone integration has been developed for cost-effective and selective glucose detection. This platform features low-cost, wax-printed micro-pads (WPµ-pads) on paper-based substrates used to construct a miniaturized CL sensor. A 3D-printed black box serves as a compact WPµ-pad sensing chamber, replacing traditional bulky equipment, such as charge coupled device (CCD) cameras and optical sensors. Smartphone integration enables a seamless and user-friendly diagnostic experience, making this platform highly suitable for point-of-care (PoC) applications. Deep learning models significantly enhance the platform’s performance, offering superior accuracy and efficiency in CL image analysis. A dataset of 600 experimental CL images was utilized, out of which 80% were used for model training, with 20% of the images reserved for testing. Comparative analysis was conducted using multiple deep learning models, including Random Forest, the Support Vector Machine (SVM), InceptionV3, VGG16, and ResNet-50, to identify the optimal architecture for accurate glucose detection. The CL sensor demonstrates a linear detection range of 10–1000 µM, with a low detection limit of 8.68 µM. Extensive evaluations confirmed its stability, repeatability, and reliability under real-world conditions. This deep learning-powered platform not only improves the accuracy of analyte detection, but also democratizes access to advanced diagnostics through cost-effective and portable technology. This work paves the way for next-generation biosensing, offering transformative potential in healthcare and other domains requiring rapid and reliable analyte detection. Full article
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12 pages, 2479 KB  
Article
Polydopamine Blending Increases Human Cell Proliferation in Gelatin–Xanthan Gum 3D-Printed Hydrogel
by Preetham Yerra, Mario Migliario, Sarah Gino, Maurizio Sabbatini, Monica Bignotto, Marco Invernizzi and Filippo Renò
Gels 2024, 10(2), 145; https://doi.org/10.3390/gels10020145 - 14 Feb 2024
Cited by 8 | Viewed by 3723
Abstract
Background: Gelatin–xanthan gum (Gel–Xnt) hydrogel has been previously modified to improve its printability; now, to increase its ability for use as cell-laden 3D scaffolds (bioink), polydopamine (PDA), a biocompatible, antibacterial, adhesive, and antioxidant mussel-inspired biopolymer, has been added (1–3% v/v) [...] Read more.
Background: Gelatin–xanthan gum (Gel–Xnt) hydrogel has been previously modified to improve its printability; now, to increase its ability for use as cell-laden 3D scaffolds (bioink), polydopamine (PDA), a biocompatible, antibacterial, adhesive, and antioxidant mussel-inspired biopolymer, has been added (1–3% v/v) to hydrogel. Methods: Control (CT) and PDA-blended hydrogels were used to print 1 cm2 grids. The hydrogels’ printability, moisture, swelling, hydrolysis, and porosity were tested after glutaraldehyde (GTA) crosslinking, while biocompatibility was tested using primary human-derived skin fibroblasts and spontaneously immortalized human keratinocytes (HaCaT). Keratinocyte or fibroblast suspension (100 µL, 2.5 × 105 cells) was combined with an uncrosslinked CT and PDA blended hydrogel to fabricate cylinders (0.5 cm high, 1 cm wide). These cylinders were then cross-linked and incubated for 1, 3, 7, 14, and 21 days. The presence of cells within various hydrogels was assessed using optical microscopy. Results and discussion: PDA blending did not modify the hydrogel printability or physiochemical characteristics, suggesting that PDA did not interfere with GTA crosslinking. On the other hand, PDA presence strongly accelerated and increased both fibroblast and keratinocyte growth inside. This effect seemed to be linked to the adhesive abilities of PDA, which improve cell adhesion and, in turn, proliferation. Conclusions: The simple PDA blending method described could help in obtaining a new bioink for the development of innovative 3D-printed wound dressings. Full article
(This article belongs to the Special Issue Hydrogels for 3D Printing)
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8 pages, 2157 KB  
Article
Real-Time Measurement of Refractive Index Using 3D-Printed Optofluidic Fiber Sensor
by João M. Leça, Yannis Magalhães, Paulo Antunes, Vanda Pereira and Marta S. Ferreira
Sensors 2022, 22(23), 9377; https://doi.org/10.3390/s22239377 - 1 Dec 2022
Cited by 7 | Viewed by 3951
Abstract
This work describes a 3D-printed optofluidic fiber sensor to measure refractive index in real time, combining a microfluidic system with an optical fiber extrinsic Fabry–Perot interferometer. The microfluidic chip platform was developed for this purpose through 3D printing. The Fabry–Perot cavity was incorporated [...] Read more.
This work describes a 3D-printed optofluidic fiber sensor to measure refractive index in real time, combining a microfluidic system with an optical fiber extrinsic Fabry–Perot interferometer. The microfluidic chip platform was developed for this purpose through 3D printing. The Fabry–Perot cavity was incorporated in the microfluidic chip perpendicularly to the sample flow, which was of approximately 3.7 µL/s. The optofluidic fiber sensor platform coupled with a low-cost optical power meter detector was characterized using different concentrations of glucose solutions. In the linear regression analysis, the optical power shift was correlated with the refractive index and a sensitivity of −86.6 dB/RIU (r2 = 0.996) was obtained. Good results were obtained in terms of stability with a maximum standard deviation of 0.03 dB and a sensor resolution of 5.2 × 10−4 RIU. The feasibility of the optofluidic fiber sensor for dynamic analyses of refractive index with low sample usage was confirmed through real-time measurements. Full article
(This article belongs to the Special Issue Micro and Nanodevices for Sensing Technology)
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16 pages, 4168 KB  
Article
Continuous Fiber-Reinforced Aramid/PETG 3D-Printed Composites with High Fiber Loading through Fused Filament Fabrication
by Sander Rijckaert, Lode Daelemans, Ludwig Cardon, Matthieu Boone, Wim Van Paepegem and Karen De Clerck
Polymers 2022, 14(2), 298; https://doi.org/10.3390/polym14020298 - 12 Jan 2022
Cited by 56 | Viewed by 7042
Abstract
Recent development in the field of additive manufacturing, also known as three-dimensional (3D) printing, has allowed for the incorporation of continuous fiber reinforcement into 3D-printed polymer parts. These fiber reinforcements allow for the improvement of the mechanical properties, but compared to traditionally produced [...] Read more.
Recent development in the field of additive manufacturing, also known as three-dimensional (3D) printing, has allowed for the incorporation of continuous fiber reinforcement into 3D-printed polymer parts. These fiber reinforcements allow for the improvement of the mechanical properties, but compared to traditionally produced composite materials, the fiber volume fraction often remains low. This study aims to evaluate the in-nozzle impregnation of continuous aramid fiber reinforcement with glycol-modified polyethylene terephthalate (PETG) using a modified, low-cost, tabletop 3D printer. We analyze how dimensional printing parameters such as layer height and line width affect the fiber volume fraction and fiber dispersion in printed composites. By varying these parameters, unidirectional specimens are printed that have an inner structure going from an array-like to a continuous layered-like structure with fiber loading between 20 and 45 vol%. The inner structure was analyzed by optical microscopy and Computed Tomography (µCT), achieving new insights into the structural composition of printed composites. The printed composites show good fiber alignment and the tensile modulus in the fiber direction increased from 2.2 GPa (non-reinforced) to 33 GPa (45 vol%), while the flexural modulus in the fiber direction increased from 1.6 GPa (non-reinforced) to 27 GPa (45 vol%). The continuous 3D reinforced specimens have quality and properties in the range of traditional composite materials produced by hand lay-up techniques, far exceeding the performance of typical bulk 3D-printed polymers. Hence, this technique has potential for the low-cost additive manufacturing of small, intricate parts with substantial mechanical performance, or parts of which only a small number is needed. Full article
(This article belongs to the Special Issue Polymer Composites for 3D Printing)
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14 pages, 2288 KB  
Article
A Portable Micro-Gas Chromatography with Integrated Photonic Crystal Slab Sensors on Chip
by Priyanka Biswas, Chen Zhang, Yudong Chen, Zhonghe Liu, Seyedmohsen Vaziri, Weidong Zhou and Yuze Sun
Biosensors 2021, 11(9), 326; https://doi.org/10.3390/bios11090326 - 9 Sep 2021
Cited by 30 | Viewed by 7809
Abstract
The miniaturization of gas chromatography (GC) systems has made it possible to utilize the analytical technique in various on-site applications to rapidly analyze complex gas samples. Various types of miniaturized sensors have been developed for micro-gas chromatography (µGC). However, the integration of an [...] Read more.
The miniaturization of gas chromatography (GC) systems has made it possible to utilize the analytical technique in various on-site applications to rapidly analyze complex gas samples. Various types of miniaturized sensors have been developed for micro-gas chromatography (µGC). However, the integration of an appropriate detector in µGC systems still faces a significant challenge. We present a solution to the problem through integration of µGC with photonic crystal slab (PCS) sensors using transfer printing technology. This integration offers an opportunity to utilize the advantages of optical sensors, such as high sensitivity and rapid response time, and at the same time, compensate for the lack of detection specificity from which label-free optical sensors suffer. We transfer printed a 2D defect free PCS on a borofloat glass, bonded it to a silicon microfluidic gas cell or directly to a microfabricated GC column, and then coated it with a gas responsive polymer. Realtime spectral shift in Fano resonance of the PCS sensor was used to quantitatively detect analytes over a mass range of three orders. The integrated µGC–PCS system was used to demonstrate separation and detection of a complex mixture of 10 chemicals. Fast separation and detection (4 min) and a low detection limit (ng) was demonstrated. Full article
(This article belongs to the Section Optical and Photonic Biosensors)
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14 pages, 3830 KB  
Article
Photoinitiator Free Resins Composed of Plant-Derived Monomers for the Optical µ-3D Printing of Thermosets
by Migle Lebedevaite, Jolita Ostrauskaite, Edvinas Skliutas and Mangirdas Malinauskas
Polymers 2019, 11(1), 116; https://doi.org/10.3390/polym11010116 - 11 Jan 2019
Cited by 100 | Viewed by 13865
Abstract
In this study, acrylated epoxidized soybean oil (AESO) and mixtures of AESO and vanillin dimethacrylate (VDM) or vanillin diacrylate (VDA) were investigated as photosensitive resins for optical 3D printing without any photoinitiator and solvent. The study of photocross-linking kinetics by real-time photorheometry revealed [...] Read more.
In this study, acrylated epoxidized soybean oil (AESO) and mixtures of AESO and vanillin dimethacrylate (VDM) or vanillin diacrylate (VDA) were investigated as photosensitive resins for optical 3D printing without any photoinitiator and solvent. The study of photocross-linking kinetics by real-time photorheometry revealed the higher rate of photocross-linking of pure AESO than that of AESO with VDM or VDA. Through the higher yield of the insoluble fraction, better thermal and mechanical properties were obtained for the pure AESO polymer. Here, for the first time, we validate that pure AESO and mixtures of AESO and VDM can be used for 3D microstructuring by employing direct laser writing lithography technique. The smallest achieved spatial features are 1 µm with a throughput in 6900 voxels per second is obtained. The plant-derived resins were laser polymerized using ultrashort pulses by multiphoton absorption and avalanche induced cross-linking without the usage of any photoinitiator. This advances the light-based additive manufacturing towards the 3D processing of pure cross-linkable renewable materials. Full article
(This article belongs to the Special Issue Thermosets II)
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10 pages, 2754 KB  
Article
Optical Fiber-Tip Sensors Based on In-Situ µ-Printed Polymer Suspended-Microbeams
by Mian Yao, Xia Ouyang, Jushuai Wu, A. Ping Zhang, Hwa-Yaw Tam and P. K. A. Wai
Sensors 2018, 18(6), 1825; https://doi.org/10.3390/s18061825 - 5 Jun 2018
Cited by 31 | Viewed by 7457
Abstract
Miniature optical fiber-tip sensors based on directly µ-printed polymer suspended-microbeams are presented. With an in-house optical 3D μ-printing technology, SU-8 suspended-microbeams are fabricated in situ to form Fabry–Pérot (FP) micro-interferometers on the end face of standard single-mode optical fiber. Optical reflection spectra of [...] Read more.
Miniature optical fiber-tip sensors based on directly µ-printed polymer suspended-microbeams are presented. With an in-house optical 3D μ-printing technology, SU-8 suspended-microbeams are fabricated in situ to form Fabry–Pérot (FP) micro-interferometers on the end face of standard single-mode optical fiber. Optical reflection spectra of the fabricated FP micro-interferometers are measured and fast Fourier transform is applied to analyze the cavity of micro-interferometers. The applications of the optical fiber-tip sensors for refractive index (RI) sensing and pressure sensing, which showed 917.3 nm/RIU to RI change and 4.29 nm/MPa to pressure change, respectively, are demonstrated in the experiments. The sensors and their optical µ-printing method unveil a new strategy to integrate complicated microcomponents on optical fibers toward ‘lab-on-fiber’ devices and applications. Full article
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18 pages, 10651 KB  
Article
Optically Clear and Resilient Free-Form µ-Optics 3D-Printed via Ultrafast Laser Lithography
by Linas Jonušauskas, Darius Gailevičius, Lina Mikoliūnaitė, Danas Sakalauskas, Simas Šakirzanovas, Saulius Juodkazis and Mangirdas Malinauskas
Materials 2017, 10(1), 12; https://doi.org/10.3390/ma10010012 - 2 Jan 2017
Cited by 126 | Viewed by 18324
Abstract
We introduce optically clear and resilient free-form micro-optical components of pure (non-photosensitized) organic-inorganic SZ2080 material made by femtosecond 3D laser lithography (3DLL). This is advantageous for rapid printing of 3D micro-/nano-optics, including their integration directly onto optical fibers. A systematic study of the [...] Read more.
We introduce optically clear and resilient free-form micro-optical components of pure (non-photosensitized) organic-inorganic SZ2080 material made by femtosecond 3D laser lithography (3DLL). This is advantageous for rapid printing of 3D micro-/nano-optics, including their integration directly onto optical fibers. A systematic study of the fabrication peculiarities and quality of resultant structures is performed. Comparison of microlens resiliency to continuous wave (CW) and femtosecond pulsed exposure is determined. Experimental results prove that pure SZ2080 is ∼20 fold more resistant to high irradiance as compared with standard lithographic material (SU8) and can sustain up to 1.91 GW/cm2 intensity. 3DLL is a promising manufacturing approach for high-intensity micro-optics for emerging fields in astro-photonics and atto-second pulse generation. Additionally, pyrolysis is employed to homogeneously shrink structures up to 40% by removing organic SZ2080 constituents. This opens a promising route towards downscaling photonic lattices and the creation of mechanically robust glass-ceramic microstructures. Full article
(This article belongs to the Special Issue Ultrafast Laser-Based Manufacturing)
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