Maji Somnath, Kwak Myounggyu, Kumar Reetesh, Lee Hyungseok
Department of Radiology, University of Michigan, Ann Arbor, MI 48109, USA.
Department of Smart Health Science and Technology, Kangwon National University (KNU), Chuncheon-si 24341, Republic of Korea.
Biosensors (Basel). 2025 Sep 17;15(9):619. doi: 10.3390/bios15090619.
Biosensors have undergone transformative advancements, evolving into sophisticated wearable and implantable devices capable of real-time health monitoring. Traditional manufacturing methods, however, face limitations in scalability, cost, and design complexity, particularly for miniaturized, multifunctional biosensors. The integration of 3D printing technology addresses these challenges by enabling rapid prototyping, customization, and the production of intricate geometries with high precision. This review explores how additive manufacturing techniques facilitate the fabrication of flexible, stretchable, and biocompatible biosensors. By incorporating advanced materials like conductive polymers, nanocomposites, and hydrogels, 3D-printed biosensors achieve enhanced sensitivity, durability, and seamless integration with biological systems. Innovations such as biodegradable substrates and multi-material printing further expand applications in continuous glucose monitoring, neural interfaces, and point-of-care diagnostics. Despite challenges in material optimization and regulatory standardization, the convergence of 3D printing with nanotechnology and smart diagnostics heralds a new era of personalized, proactive healthcare, offering scalable solutions for both clinical and remote settings. This synthesis underscores the pivotal role of additive manufacturing in advancing wearable and implantable biosensor technology, paving the way for next-generation devices that prioritize patient-specific care and real-time health management.
