M-ERA.Net Project to Develop High Volume Manufacturing for Graphene-Based Biosensors

Haydale has announced its partnership in BIOGRAPHY, a breakthrough project backed by EU funding network, M-ERA.Net. Utilizing Haydale’s HDPlas graphene-based conductive inks, the project is set to establish a highly cost-effective mass fabrication process for graphene-based biosensors with significant impact expected for applications in healthcare and environmental protection.

M-ERA.Net is an EU-funded network which was established to support and increase the coordination of European research programs and related funding in materials science and engineering.

The three-year project, which commenced in October, is a collaborative venture between Haydale, Fraunhofer IBMT, Sauressig, AiCuris and cellasys aiming to print graphene electrodes with biofunctional coatings on large-area polymer foils via a roll-to-roll process, similar to the printing of newspapers. Through the development of this high-speed manufacturing process, the project is set to enable a mass fabrication process for graphene-based biosensors for the first time. This will enable significant reductions to be made in manufacturing costs for medical applications such as detectors of pesticides, airborne pathogens, drug residues and antibiotics, glucose monitors and other health screening devices.

BIOGRAPHY will undertake several steps to achieve this development over the three-year period, including the production of a biocompatible, electrically conductive graphene ink (to be provided by Haydale) for rotogravure printing and a fabrication method for micro (< 10 µm) patterning of gravure printing cylinders. The project will then develop the roll-to-roll process and production line for the surface functionalization of large polymer foils by gravure printing of a micro-patterned graphene/protein multiplayer, and will provide a proof of suitability for the printed multilayer for two different biosensor applications.

“Biosensors are becoming increasingly sophisticated and biosensor devices are now extremely effective at detecting a large variety of analytes including organic compounds, gases, ions and bacteria. However, the materials and processes used to manufacture these sensors are expensive, leading to costs to the end user which often exceed that of the sensor device itself,” said Chris Spacie, CTO at Haydale.

“Graphene’s electrocatalytic properties make it a perfect material for biosensor technology and its multiple forms make it a suitable transducer for a wide range of biosensors,” Dr. Spacie added. “Haydale’s customized surface functionalization capability is ideal for the production of a biocompatible, electrically conductive graphene-based ink customized for this application and for implementation into a mass roll-to-roll fabrication process. Through this method, the project is set to produce cost effective, high-performance graphene-based biosensors for the first time.”

“The new M-ERA.Net funded project presents an excellent opportunity for graphene’s extraordinary electrical conductivity and electrocatalytic properties to be realized,” said Ray Gibbs, CEO of Haydale. “Our low temperature, proprietary plasma functionalization process provides the capability to develop biocompatible, graphene-based inks customized for this specific application. By successfully developing a process that will significantly reduce biosensor manufacturing costs, graphene will prove a commercially viable solution over existing materials. Thanks to our partners at Fraunhofer IBMT, Saueressig, AiCuris and cellasys, BIOGRAPHY has the potential to provide a platform for graphene to achieve commercialization.”