University of Derby Tests 3D-Printed Biosensors for Rapid Deployment

What they built

Researchers at the University of Derby published a study evaluating three common FFF filaments as platforms for rapidly deployable electrochemical biosensors. The work, by Bethany Richardson and Urvashi Gunputh, appears in the International Journal of Advanced Manufacturing Technology.

The team printed identical sensor geometries using conductive PLA, graphene-enhanced PLA, and standard PLA on an Ultimaker S5. They then measured dimensional accuracy, surface morphology, fluid flow behavior, and baseline electrical performance. The goal was to find a material that can be printed in hours rather than weeks for defense testing, disaster response, and field diagnostics.

Why it matters

Most 3D-printed biosensor research focuses on the biological layer that detects pathogens or chemicals. That layer is only half the system. The printed structure underneath must also provide accurate geometry, controlled fluid flow, and stable electrical performance before any biofunctionalization takes place.

Standard PLA proved to be an excellent insulator, making it unsuitable as an electrode. Conductive PLA provided reliable electrical performance but with some consistency issues. Graphene-enhanced PLA combined lower resistance with good print quality and dimensional consistency, giving it the strongest overall balance for future biosensor development.

What the tests showed

Computational fluid dynamics simulations confirmed that the serpentine sensing architecture supports stable laminar flow across the active sensing region. Electrical testing reinforced that graphene-enhanced PLA delivered the most favorable balance between conductivity, signal stability, and manufacturing consistency.

The researchers have not yet produced a working biosensor with biological components. This work sets the stage for later phases that will add graphene-based surface treatments, hydrogels, antibodies, and aptamers before evaluating electrochemical impedance under realistic conditions.

The bottom line

If those next steps succeed, this approach could shorten development cycles for applications where replacement sensors need to be printed within hours instead of weeks. The team has already established a systematic engineering process for selecting printable materials before expensive biological components are ever introduced.