polyHWG: 3D Printed Substrate-Integrated Hollow Waveguides for Mid-Infrared Gas Sensing.

Gas analysis via mid-infrared (MIR) spectroscopic techniques has gained significance due to its inherent molecular selectivity and sensitivity probing pronounced vibrational, rotational, and roto-vibrational modes. In addition, MIR gas sensors are suitable for real-time monitoring in a wide variety of sensing scenarios. Our research team has recently introduced so-called substrate-integrated hollow waveguides (iHWGs) fabricated by precision milling, which have been demonstrated to be useful in online process monitoring, environmental sensing, and exhaled breath analysis especially if low sample volumes (i.e., few hundreds of microliters) are probed with rapid signal transients. A logical next step is to establish ultralightweight, potentially disposable, and low-cost substrate-integrated hollow waveguides, which may be readily customized and tailored to specific applications using 3D printing techniques. 3D printing provides access to an unprecedented variety of thermoplastic materials including biocompatible polylactides, readily etchable styrene copolymers, and magnetic or conductive materials. Thus, the properties of the waveguide may be adapted to suit its designated application, e.g., drone-mounted ultralightweight waveguides for environmental monitoring or biocompatible disposable sensor interfaces in medical/clinical applications.