A durable, stretchable, and disposable electrochemical biosensor on three-dimensional micro-patterned stretchable substrate

A durable, stretchable, and disposable electrochemical immunosensor fabricated on a 3D micro-patterned elastomeric substrate on which distinctive 3D microstructures alleviated the stress applied to the sensor is demonstrated for the detection of immunoreactions. A stretchable electrochemical immunosensor with excellent capability of detecting specific protein biomarkers is promising for integration into body-attachable immunosensing platforms for diagnosis of various diseases from body fluids. [Display omitted] •A stretchable and disposable electrochemical biosensor for tumor necrosis factor-α (TNF-α) is constructed.•This electrochemical biosensor is fabricated on a distintive 3D micro-patterened elastomer for stretchable applications.•High stability of electrochemical signal under stretched state and cyclic stretching up to 30% is achieved.•This biosensor permits a detection TNF-α cytokine ranging from 100 fM to 100 nM in human serum under 30% elongation. Stretchable and disposable electrochemical biosensors as a new immunosensing platform are of great interest for the detection of biomarkers from body fluids including tears, interstitial fluids, sweat, or wound fluids. However, realization of such stretchable electrochemical biosensors has been limited by hurdles of obtaining electrochemical electrodes with high sensitivity, stretchability, and durability under mechanical deformation. Herein, a durable, stretchable, and disposable electrochemical biosensor fabricated by forming thermally evaporated Au working and counter electrodes and a stencil-printed Ag/AgCl reference electrode on a three-dimensional, micro-patterned stretchable substrate with curvilinearly connected bumps and valleys for efficient stress relief under stretching is reported. As an example of target biomolecule, tumor necrosis factor-α (TNF-α) cytokine in human serum ranging from 100 fM to 100 nM, a wound healing parameter, was detected using TNF-α antibody as a probe. The results show high stability of the sensing signal indicating minimal stretch-induced artefacts under a stretched state up to 30% and twisting. The device is also mechanically and electrochemically stable after cyclic stretching at 30% elongation. The device holds great potential for further integration into a body-attachable immunosensing platform, which is promising for the immunodetection of biomarkers in a wearable format.