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3D-printed microneedles for sensing applications: Emerging topics and future trends

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Author(s):
Teodoro, Kelcilene B. R. ; Pereira, Tamires S. ; Alves, Ana Laura M. M. ; dos Santos, Francisco V. ; dos Santos, Fabricio A. ; Correa, Daniel S.
Total Authors: 6
Document type: Journal article
Source: ADVANCED SENSOR AND ENERGY MATERIALS; v. 4, n. 2, p. 22-pg., 2025-05-12.
Abstract

3D-printed microneedles (MNs) have revolutionized the biomedical sector, enabling applications in aesthetic treatments, vaccine delivery, diagnostics, and real-time biomarker analysis. These minimally invasive structures advance the development of sensors and biosensors for diverse applications, including human, veterinary, agricultural, and environmental domains. Recent trends favor MNs made from polymers and nanomaterials over traditional metals, addressing challenges related to cost, biocompatibility, and scalability. In this context, this review explores recent advancements on different MNs-based sensors, fabricated by 3D printing, highlighting innovations, shortcomings and also pointing future opportunities to expand their applications in medical, agricultural and environmental domains. Initially, we discuss the general aspects of planning an efficient MN's design (encompassing possible types and required properties), as well as the choice of materials and manufacturing techniques for 3D printing polymeric MNs. Next, we examine the relationship between printing techniques, the manufactured MNs, and their integration with sensors, followed by examples of studies that explore this connection. Key innovations include the use of biodegradable resins, nanocomposites, artificial intelligence, and machine learning for design optimization. While biomedical applications dominate, we highlight significant opportunities for MNs in agriculture and environmental monitoring through tailored manufacturing approaches. (AU)

FAPESP's process: 23/01567-6 - Conductive composite microneedles manufactured by 3D printing and applications in wearable biosensors
Grantee:Daniel Souza Corrêa
Support Opportunities: Regular Research Grants
FAPESP's process: 22/09686-1 - Hybrid nanomaterials applied in portable sensory platforms.
Grantee:Fabrício Aparecido dos Santos
Support Opportunities: Scholarships in Brazil - Post-Doctoral
FAPESP's process: 23/13428-0 - Conductive composite microneedles manufactured by 3D printing and applications in wearable biosensors
Grantee:Kelcilene Bruna Teodoro Costa
Support Opportunities: Scholarships in Brazil - Support Program for Fixating Young Doctors
FAPESP's process: 22/05316-5 - Development of functional polymeric biomaterials aimed at tissue regeneration and healing
Grantee:Francisco Vieira dos Santos
Support Opportunities: Scholarships in Brazil - Doctorate
FAPESP's process: 20/10048-4 - Development of wearable sensors based on nanomaterials to detect fungal diseases in plants
Grantee:Tamires dos Santos Pereira
Support Opportunities: Scholarships in Brazil - Doctorate