Harnessing the potential of emerging additive manufacturing technologies as a game-changer for chemical and biosensing innovations

Over the past four decades, additive manufacturing (AM), particularly three-dimensional (3D) printing, has emerged as a transformative force in chemical and biosensing technologies, revolutionizing prototyping and production across laboratories and industries. Recent advancements in 3D printing techniques and materials have accelerated the development of novel sensors for diverse applications, offering unparalleled advantages such as rapid prototyping, customization, and cost efficiency. Unlike traditional fabrication methods, 3D printing creates intricate, high-precision structures while reducing multi-step processes, making it ideal for biosensing applications. Its interdisciplinary potential spans physics, chemistry, engineering, biology, and medicine, positioning it as a transformative tool in biomedical applications, including biosensing. Despite its remarkable promises, some challenges such as limited multi-material integration, standardization hurdles, resolution constraints, biocompatibility concerns, and scalability issues persist. Addressing these gaps through interdisciplinary collaboration could unlock the full potential of AM-enabled sensing devices. This review critically evaluates the evolution and latest progress in AM technologies, including fused deposition modeling, stereolithography, and inkjet printing for designing sensitive, customizable, and affordable biosensing platforms and devices. Additionally, this article explores recent innovations in 3D-printed chemical and biological sensors, analyzing their performance in detecting various analytes. A comprehensive summary of cutting-edge developments is provided, alongside an examination of future directions for refining and inventing 3D printing techniques in biosensing applications. Finally, the review highlights current challenges and opportunities in 3D-printed sensing devices, emphasizing the need for material optimization, improved printing resolution, and enhanced device functionality. By overcoming these barriers, 3D printing can serve as a cornerstone for next-generation diagnostic platforms, driving innovation in chemical and biosensing technologies. This review underscores AM’s transformative role as a catalyst for future breakthroughs in the field.