K. Länge

Let there be chip—towards rapid prototyping of microfluidic devices: one-step manufacturing processes

Microfluidics is an evolving scientific field with immense commercial potential: analytical applications, such as biochemical assay development, biochemical analysis and biosensors as well as chemical synthesis applications essentially require microfluidics for sample handling, treatment or readout. A number of techniques are available to create microfluidic structures today. On industrial scale replication techniques such as injection molding are the gold standard whereas academic research mostly focuses on replication by casting of soft elastomers such as polydimethylsiloxane (PDMS). Both of these techniques require the creation of a replication master thus creating the microfluidic structure only in the second process step—they can therefore be termed two-(or multi-)step manufacturing techniques. However, very often the number of pieces to be created of one specific microfluidic design is low, sometimes even as low as one. This raises the question if two-step manufacturing is an appropriate choice, particularly if short concept-to-chip times are required. In this case one-step manufacturing techniques that allow the direct creation of microfluidic structures from digital three-dimensional models are preferable. For these processes the number of parts per design is low (sometimes as low as one), but quick adaptation is possible by simply changing digital data. Suitable techniques include, among others, maskless or mask based stereolithography, fused deposition molding and 3D printing. This work intends to discuss the potential and application examples of such processes with a detailed view on applicable materials. It will also point out the advantages and the disadvantages of the respective technique. Furthermore this paper also includes a discussion about non-conventional manufacturing equipment and community projects that can be used in the production of microfluidic devices.

Biosensors with label-free detection designed for diagnostic applications

AbstractSince the first biosensor was introduced in 1962 by Clark and Lyons, there has been increasing demand for such analytical devices in diagnostic applications. Research initially focussed mainly on detector principles and recognition elements, whereas the packaging of the biosensors and the microfluidic integration has been discussed only more recently. However, to obtain a user-friendly and well-performing analytical device, those components have to be considered all together. This review outlines the requirements and the solutions suggested for the integration of suitable biosensors in packaging and the integration of those encapsulated biosensors into a microfluidic surrounding resulting in a complete and efficient analytical device for diagnostic applications. The components required for a complete biosensor instrument are described and the latest developments which meet the requirements for diagnostic applications, such as single-use components and arrays for multiparameter detection, are discussed. The current state and the future of biosensors in the field of clinical diagnostics are outlined, particularly on the basis of label-free assay formats and the detection of prominent biomarkers for cancer and autoimmune disorders. Figure CaptionComponents to be considered in an efficient biosensor system

Influence of intermediate aminodextran layers on the signal response of surface acoustic wave biosensors

Surface acoustic wave (SAW) devices based on horizontally polarized surface shear waves enable direct and label-free detection of proteins in real time. Binding reactions on the sensor surface are detected by determining changes in surface wave velocity caused mainly by mass adsorption or change of viscoelasticity in the sensing layer. Intermediate hydrogel layers have been proven to be useful to immobilize capture molecules or ligands corresponding to the analyte. However, the SAW signal response strongly depends on the morphology of the hydrogel due to different relative changes of its acoustomechanical parameters such as viscoelasticity and density. In this work five aminodextrans (AMD) and one diamino polyethylene glycol (DA-PEG) were used as intermediate hydrogel layers. Sensors with immobilized streptavidin and samples containing biotinylated bovine serum albumin were used to exemplify affinity assays based on immobilized capture molecules for protein detection. The effects of the three-dimensional AMDs and the two-dimensional (2D) DA-PEG on the SAW signal response were investigated. The signal height decreased with increasing molar mass and increasing amount of immobilized AMD. Consequently, thin hydrogel layers are ideal to obtain optimum signal responses in this type of assay, whereas it is not necessarily a 2D hydrogel that gives the best results.

Characterization of antibodies against benzo[a]pyrene with thermodynamic and kinetic constants

Antibodies of a polyclonal antiserum against benzo[a]pyrene were characterized by determining thermodynamic and kinetic constants of the antigen-antibody reaction. Label-free binding assays with optical detection based on reflectometric interference spectroscopy were performed to determine these constants. Different evaluation methods for kinetic measurements were compared. Also, cross-reactivity against two other polycyclic aromatic hydrocarbons, chrysene and pyrene, was checked. The affinity constant between the antibodies and benzo[a]pyrene in homogeneous phase was determined to be K=(5.3+/-0.3)x10(7) M(-1) which was in the middle of the usual range of antibody affinities. The association rate constant for the reaction at the surface was determined to be (3.8+/-0.9)x10(5) M(-1) s(-1), the dissociation rate constant as (9.7+/-0.5)x10(-3) s(-1). Different evaluation methods applied to the kinetic measurements led to the same results. This antiserum would be suitable for the selective determination of benzo[a]pyrene in concentrated samples.

Rapid bonding of polydimethylsiloxane to stereolithographically manufactured epoxy components using a photogenerated intermediary layer.

We describe a low cost, photo-induced, room-temperature bonding technique for bonding epoxy components to flexible PDMS membranes in less than half an hour. Bond strengths (~350 kPa) were characterized by ISO-conform tensile testing for a popular stereolithography resin and found comparable bond strengths as reported for PDMS/PDMS bonds.

Surface Acoustic Wave (SAW) Resonators for Monitoring Conditioning Film Formation

We propose surface acoustic wave (SAW) resonators as a complementary tool for conditioning film monitoring. Conditioning films are formed by adsorption of inorganic and organic substances on a substrate the moment this substrate comes into contact with a liquid phase. In the case of implant insertion, for instance, initial protein adsorption is required to start wound healing, but it will also trigger immune reactions leading to inflammatory responses. The control of the initial protein adsorption would allow to promote the healing process and to suppress adverse immune reactions. Methods to investigate these adsorption processes are available, but it remains difficult to translate measurement results into actual protein binding events. Biosensor transducers allow user-friendly investigation of protein adsorption on different surfaces. The combination of several transduction principles leads to complementary results, allowing a more comprehensive characterization of the adsorbing layer. We introduce SAW resonators as a novel complementary tool for time-resolved conditioning film monitoring. SAW resonators were coated with polymers. The adsorption of the plasma proteins human serum albumin (HSA) and fibrinogen onto the polymer-coated surfaces were monitored. Frequency results were compared with quartz crystal microbalance (QCM) sensor measurements, which confirmed the suitability of the SAW resonators for this application.

Surface modification of an acoustic biosensor allowing the detection of low concentrations of cancer markers.

Analyte detection with biosensors is strongly influenced by the preparation of the biosensor surface including choice of sensing layers and coupling methods for corresponding capture molecules. We investigated the influence of different coupling procedures, especially considering coupling chemistry and incubation times for reagents, by means of surface acoustic wave (SAW) biosensors. The effect on the signal response was tested in two subsequent protein assays. Our optimized coupling procedure allowed the detection of the breast cancer markers HER-2 (human epidermal growth factor receptor-2) and TIMP-1 (tissue inhibitor of metalloproteinase-1) below the respective clinical cutoff values of only a few nanograms per milliliter.

Biosensors coated with sulfated polysaccharides for the detection of hepatocyte growth factor/scatter factor in cell culture medium

Process control methods for cell culture bioreactors include on-line monitoring of protein concentrations. Bioreactor samples typically contain high amounts of different proteins. The direct detection of a single protein in this complex medium is a challenging task within the development of biosensors with label-free detection. We introduce the development of a mass-sensitive biosensor based on surface acoustic waves (SAW) for the detection of hepatocyte growth factor/scatter factor (HGF/SF) in the serum containing medium of a miniaturized bioreactor for culturing hepatocytes. The specificity of the biosensor was obtained following two approaches. In the first approach, antibodies against HGF (anti-HGF) were immobilized covalently via an intermediate layer of dicarboxy polyethylene glycol on the biosensor surface. In the second approach, dextran sulfate and fucoidan were used as sensor coatings exploiting the fact that HGF binds specifically to those sulfated polysaccharides. Performing HGF assays, similar results were obtained using biosensors coated with dextran sulfate and biosensors coated with anti-HGF. Even higher sensor signals were obtained using biosensors coated with fucoidan, particularly at 37°C. Therefore, biosensor coatings based on biospecific sulfated polysaccharides offer a simple and cost-saving alternative compared to the commonly used coating with antibodies.

Polymer coating behavior of Rayleigh-SAW resonators with gold electrode structure for gas sensor applications

Results from systematic polymer coating experiments on surface acoustic wave (SAW) resonators and coupled resonator filters (CRF) on ST-cut quartz with a corrosion-proof electrode structure entirely made of gold (Au) are presented and compared with data from similar SAW devices using aluminium (Al) electrodes. The recently developed Au devices are intended to replace their earlier Al counterparts in sensor systems operating in highly reactive chemical gas environments. Solid parylene C and soft poly[chlorotrifluoroethylene-co-vinylidene fluoride] (PCFV) polymer films are deposited under identical conditions onto the surface of Al and Au devices. The electrical performance of the Parylene C coated devices is monitored online during film deposition. The PCVF coated devices are evaluated after film deposition. The experimental data show that the Au devices can stand up to 40% thicker solid films for the same amount of loss increase than the Al devices and retain better resonance and phase characteristics. The frequency sensitivities of Au and Al devices to parylene C deposition are nearly identical. After coating with soft PCFV sensing film, the Au devices provide up to two times higher gas sensitivity when probed with cooling agent, octane, or tetrachloroethylene

Acoustic Biosensors Coated With Phosphorylcholine Groups for Label-Free Detection of Human C-Reactive Protein in Serum

Mass-sensitive biosensor devices based on surface acoustic waves (SAWs) were coated with commercially available 2-methacryloyloxyethyl phosphorylcholine (MPC) polymer for label-free detection of the inflammatory marker C-reactive protein (CRP) in human serum. Owing to the phosphorylcholine groups, the MPC polymer coating enables both binding of CRP and reduction of nonspecific adsorption of other proteins. Hence, MPC offers a simple and economic method to prepare CRP-specific biosensing layers without the use of additional capture molecules. Direct detection and a binding inhibition assay test format were used, where the latter was applied to minimize effects from the serum sample matrix. MPC polymer coated SAW biosensors could be used with both test formats to differentiate CRP serum concentrations in the normal range (i.e., 10 mg/L and below) from significantly increased serum concentrations which would indicate bacterial infection, tissue injury, and inflammation.