Roll-to-Roll Gravure Printed Electrochemical Sensors for Wearable and Medical Devices
Open accessAbstract
As recent developments in noninvasive biosensors spearhead the thrust toward personalized health and fitness monitoring, there is a need for high throughput, cost-effective fabrication of flexible sensing components. Toward this goal, we present roll-to-roll (R2R) gravure printed electrodes that are robust under a range of electrochemical sensing applications. We use inks and electrode morphologies designed for electrochemical and mechanical stability, achieving devices with uniform redox kinetics printed on 150 m flexible substrate rolls. We show that these electrodes can be functionalized into consistently high performing sensors for detecting ions, metabolites, heavy metals, and other small molecules in noninvasively accessed biofluids, including sensors for real-time, in situ perspiration monitoring during exercise. This development of robust and versatile R2R gravure printed electrodes represents a key translational step in enabling large-scale, low-cost fabrication of disposable wearable sensors for personalized health monitoring applications.
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R2R-compatible methods are advantageous over traditional, multistep lithography and etching processes as components can be mass produced on large substrate areas at high speeds using automated systems with minimal human involvement.
“These R2R-compatible methods are advantageous over traditional, multistep lithography and etching processes as components can be mass produced on large substrate areas at high speeds using automated systems with minimal human involvement (41).”
From Regional and correlative sweat analysis using high-throughput microfluidic sensing patches toward decoding sweat (2019) · cites this paper as [41]
The Abstract says R2R printing offers high-speed, large-area fabrication advantages over photolithography, and the R2R Gravure Printing section reports producing 150,000 electrodes on a 150 m web in about 30 minutes. The copy does not establish the comparison with etching or the claim that production requires minimal human involvement. Page numbers are not available in the supplied copy. (LLM, conf=0.85)
Experimental — accuracy not yet measuredThe system presented here demonstrates R2R fabrication of integrated sweat rate sensors and microfluidics, representing a key application-oriented technological advancement that can help decode the rate-dependent modulation of sweat analyte secretion.
“While R2R printing of electrochemical electrodes and microfluidic structures has been previously and independently introduced, the system presented here further demonstrates R2R fabrication of integrated sweat rate sensors and microfluidics, representing a key application-oriented technological advancement that can help decode the rate-dependent modulation of sweat analyte secretion (41, 42).”
From Regional and correlative sweat analysis using high-throughput microfluidic sensing patches toward decoding sweat (2019) · cites this paper as [41]
Bariya et al.'s roll-to-roll gravure printed electrochemical electrodes on flexible PET achieved devices with uniform redox kinetics for detection of pH, K+, Na+, Cu2+, glucose, and caffeine.
“Bariya et al.66 developed roll-to-roll (R2R) gravure printed electrochemical electrodes on 150 m flexible PET substrate rolls for the detection of pH, K+, Na+, Cu2+, glucose, and caffeine (Fig. 2a, b). The team utilized inks and electrode morphologies designed for electrochemical and mechanical stability to achieve devices with uniform redox kinetics.”
From Wearable sensors for monitoring the physiological and biochemical profile of the athlete (2019) · cites this paper as [66]
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- Authors
- Bariya, M., Shahpar, Z., Park, H., Sun, J., Jung, Y., Gao, W., Nyein, H. Y. Y., Liaw, T. S., Tai, L.-C., Ngo, Q. P., Chao, M., Zhao, Y., Hettick, M., Cho, G., & Javey, A.
- Affiliations
- Lawrence Berkeley National Laboratory (US)
- Sunchon National University (KR)
- Corresponding author
- Cho, Gyoujin
- Javey, Ali
- ORCID
- Venue
- ACS Nano
- Publisher
- American Chemical Society (ACS)
- Published
- 2018-06-20
- Volume
- 12
- Issue
- 7
- Pages
- 6978-6987
- ISSN
- 1936-0851 (ISSN-L)
- 1936-086X
- OpenAlex
- W2808848509
- Cited by
- 417
- References
- 47
- Citations by year
- 2026: 42 · 2025: 48 · 2024: 53 · 2023: 57 · 2022: 73 · 2021: 61 · 2020: 51 · 2019: 28 · 2018: 4
- FWCI
- 13.76
- Type
- journal article
- Language
- en
- Open access
- green
- www.osti.gov
- Locations
- ACS Nano (publishedVersion)
- PubMed (publishedVersion)
- OSTI OAI (U.S. Department of Energy Office of Scientific and Technical Information) (submittedVersion)
- eScholarship (California Digital Library) (submittedVersion)
- Rare & Special e-Zone (The Hong Kong University of Science and Technology) (submittedVersion)
- Funders
- Division of Engineering Education and Centers
- Ministry of Food and Drug Safety, Republic of Korea (16163KKMFDS001)
- Berkeley Sensor and Actuator Center, University of California, Berkeley
- Topics
- Physical Sciences › Engineering › Electrical and Electronic Engineering › Electrochemical sensors and biosensors
- Physical Sciences › Engineering › Electrical and Electronic Engineering › Nanomaterials and Printing Technologies
- Physical Sciences › Engineering › Biomedical Engineering › Advanced Sensor and Energy Harvesting Materials
- Keywords
- printed electrodes, flexible electronics, wearable sensors, exercise monitoring, disposable sensors, ion detection, metabolite detection, heavy metal detection, biological fluids, personalized health monitoring, redox kinetics, flexible substrates
- MeSH terms
- Wearable Electronic Devices, Electrodes, Printing, Electrochemical Techniques
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