Low Cost 3D-Printed Biosensor Arrays for Protein-based Cancer Diagnostics based on Electrochemiluminescence

Development and fabrication of bioanalytical devices by 3D printing offers revolutionary new routes to low cost clinical diagnostic devices for molecular measurements. Relevant to future protein-based cancer diagnostics, we describe and review here our recent development of prototype protein immunoarray devices using desktop Fused Deposition Modeling (FDM) and stereolithographic 3D printers. All these system feature sensitive electro-optical detection by a method called electrochemiluminescence (ECL). Our first 3D-printed immunoarray features screen-printed sensors in which manual manipulations enable gravity flow reagent delivery for measurement of 3 proteins at detection limits of 0.3 to 0.5 pg/mL. ECL detection is achieved in an open channel on integrated disposable screen-printed sensor elements. We then address the issue of printing and processing optically clear plastic using a stereolithographic printer to build a closed ECL detection chamber. Finally, we describe a prototype 3D-printed microprocessor-controlled enclosed microfluidic ECL immunoarray featuring reagent reservoirs, micropumps and clear plastic detection chamber with printed nanowells for ECL emission.