Xurography-fabricated copper thin film functionalized with electrodeposited dendritic gold for sweat glucose sensing

Glucose monitoring is essential for effective diabetes management and for reducing the risk of long-term complications. In this work, we present a low-cost, enzyme-free electrochemical platform for sweat glucose sensing, fabricated using rapid xurography and 3D printing. This portable benchtop sensing platform is constructed with a polydimethylsiloxane (PDMS) microfluidic chip, a PDMS encapsulation layer, a copper thin film electrode, and electrodeposited dendritic gold nanostructures, all embedded in a polylactic acid polymer holder. The two-inlet microfluidic configuration enables pump-free operation and provides in situ sweat pH regulation, ensuring stable glucose detection under physiologically relevant conditions. For the first time, copper oxide/copper thin film electrodes were functionalized with dendritic Au nanostructures via electrodeposition, significantly enhancing electrochemical performance. Under optimized conditions, the sensor achieved a wide linear range of 50 μM-1 mM, high sensitivity of 2889.3 μA·mM −1 ·cm −2 , excellent reproducibility (RSD % = 3.36 %), good reusability (~ 91 % signal retention after four cyclic voltammetry cycles), and long-term stability (89.6 % retention after four weeks of storage). The sensor also demonstrated robust selectivity in artificial sweat, maintaining ~87–90 % of its glucose signal in the presence of common interferents such as ascorbic acid and sodium chloride. Moreover, the platform exhibited reusability, portability, easy scalability, and a high sensitivity of 2007.9 μA·mM −1 ·cm −2 in artificial sweat, highlighting its potential for real-time, non-invasive glucose monitoring. Given its affordability, simplicity, and strong analytical performance, this sensing system represents a promising point-of-care technology, particularly relevant for low- and middle-income countries, where accessible diabetes management tools are urgently needed.