Strategies for passivating microneedle-based sensors: development, characterization and comparison

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dc.contributor.authorBocchino, Andreaen
dc.contributor.authorRodrigues Teixeira, Sofiaen
dc.contributor.authorBarry, Fionaen
dc.contributor.authorThatte, Chinmayen
dc.contributor.authorRyan, Adamen
dc.contributor.authorRahman, Fahimaen
dc.contributor.authorHu, Yuanen
dc.contributor.authorIadanza, Simoneen
dc.contributor.authorGalvin, Paulen
dc.contributor.authorKurzhals, Steffenen
dc.contributor.authorMelnik, Evaen
dc.contributor.authorMutinati, Giorgio C.en
dc.contributor.authorO'Mahony, Conoren
dc.contributor.funderHigher Education Authorityen
dc.contributor.funderEuropean Regional Development Funden
dc.contributor.funderHorizon 2020en
dc.contributor.funderEnterprise Irelanden
dc.date.accessioned2025-04-30T08:44:43Z
dc.date.available2025-04-30T08:44:43Z
dc.date.issued2025en
dc.description.abstractMicroneedles (MNs) are sharp, pillar-like structures shorter than 1 mm. They can painlessly pierce the stratum corneum (SC), the outermost layer of the skin, and interface with the underlying dermal interstitial fluid, rich in biomarkers. Due to these properties, MNs have been widely investigated for several diagnostic applications. In particular, MN-based biosensors could enable the development of the new generation of minimally invasive continuous monitoring systems. To become a biosensor, the body or the tip of the needles must be functionalized. In addition, the area surrounding the MNs is usually passivated to prevent substrate interferences. Although passivation layers are widely used, there is a lack of characterization of such layers. This work aims at filling this gap, by developing, characterizing, and comparing six different passivation techniques. These include the application of polymethyl methacrylate (PMMA), Epotek 353ND, silicon oxide (SiO2), parylene, varnish and an adhesive film to microneedle arrays. The performance of each method was then assessed using electrochemical measurements, optical and SEM imaging, and contact angle analysis. Significant variability was observed across the various methods and materials. When assessed in terms of the electrochemically active area available after passivation, the tape and parylene were the most promising layers, while varnish and epoxy were the worst performing materials. The PMMA performed better than the other liquid passivations, but still requires refinement due to the high degree of unwanted coverage of the needles. Finally, the SiO2 layer seemed to be a viable option, but also remains in need of additional optimization.en
dc.description.sponsorshipHorizon 2020 (825549); Enterprise Ireland (IRF/2022/0066, 101095792)en
dc.description.sponsorshipResearch Ireland (SFI/12/RC/2289-P2)en
dc.description.statusPeer revieweden
dc.description.versionPublished Versionen
dc.format.mimetypeapplication/pdfen
dc.identifier.articleid100328en
dc.identifier.citationBocchino, A., Teixeira, S. R., Barry, F., Thatte, C., Ryan, A., Rahman, F., Hu, Y., Iadanza, S., Galvin, P., Kurzhals, S. and Melnik, E. (2025) 'Strategies for passivating microneedle-based sensors: development, characterization and comparison', Sensors and Actuators Reports, 9, p.100328. DOI: 10.1016/j.snr.2025.100328en
dc.identifier.doi10.1016/j.snr.2025.100328en
dc.identifier.issn26660539en
dc.identifier.journaltitleSensors and Actuators Reportsen
dc.identifier.urihttps://hdl.handle.net/10468/17365
dc.identifier.volume9
dc.language.isoenen
dc.publisherElsevier B.V.en
dc.relation.project825549
dc.relation.projectIRF/2022/0066
dc.relation.project101095792
dc.relation.projectSFI/12/RC/2289-P2
dc.rights© 2025, the Author(s). Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/)en
dc.rights.urihttps://creativecommons.org/licenses/by/4.0/
dc.subjectElectrochemistryen
dc.subjectMicroneedlesen
dc.subjectPassivationen
dc.subjectSensorsen
dc.titleStrategies for passivating microneedle-based sensors: development, characterization and comparisonen
dc.typeArticle (peer reviewed)en
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