Interfacial Dynamics in the Fabrication of Various Concave Hydrogel Discs for Enhanced Biosensing

Hydrogel-based biosensors are commonly used in diagnostic applications. However, their performance remains constrained by slow analyte diffusion within polymer matrices, particularly when larger biomolecules are involved. Concave hydrogel geometries present a promising solution to enhance diffusion rates through increased surface area. However, the interfacial dynamics governing their formation must be studied. In this research, we investigated the interfacial dynamics that influence the formation of concave hydrogel discs fabricated by a simple pipetting method. We characterized the fluid interactions occurring during droplet deposition of alginate and CaCl₂ solutions. A three-phase flow model incorporating confocal microscopy validation was employed to simulate time-dependent interfacial behaviors. Concave hydrogel discs fabricated with alginate-first deposition exhibited 83% larger surface area compared to hemispherical counterparts at a CaCl₂: alginate volume ratio of one. Increasing the volume ratio further enhanced both surface area and diameter, though this highlighted limitations for microscopy-based detection. According to our results, reaction speed in alginate concave hydrogel discs can be controlled by varying the volume of CaCl₂ solution while keeping the volume of alginate solution constant, which changes the surface area while maintaining constant hydrogel volume.