Food production, environmental protection, biotechnology, and medicine, all depend on biosensors for measuring specific biological molecules. Among biosensors, enzymatic electrochemical biosensors have received particular attention due to their simple operation and enzymes’ inherent specificity. Researchers have extensively explored novel materials and biological designs to improve performance (i.e., sensitivity, linearity, limit of detection, and response time). However, in comparison, physical and geometrical design has not received the same attention. To this end, we compared platinum (Pt) microelectrodes with circular or fractal geometry with the same surface area (2D geometry). We also studied the effect of 3D geometry by nanostructuring both circular and fractal microelectrodes via electroplating Pt black. Fractal Pt black microelectrodes displayed the highest current density, charge storage capacity, and sensitivity towards H2O2. Next, we immobilized glucose oxidase onto various microelectrode geometries by microcontact stamping. Fractal Pt and Pt black glucose biosensors were 91.7% and 83.3% more sensitive than circular counterparts. Circular and fractal Pt black glucose biosensors were 63.0% and 55.9% more sensitive than Pt counterparts. Fractal geometry also provided better linearity and limit of detection. We modified enzyme layer thickness through multiple layer stamping and found a trade-off whereby increasing thickness increased sensitivity but also increased response time. Lastly, we developed a COMSOL Multiphysics numerical model to interpret the amperometric data and the impact of physical design on critical parameters. The work here will serve as a guideline for improving enzymatic electrochemical and other biosensors via physical design, which is simpler to modify than material or biological design.
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