Advanced Fabrication Techniques and Case Studies in Biosensor Technology: A Review

Introduction: Biosensors are highly sensitive and specific analytical devices designed to detect and quantify biological or chemical substances. With advancements in fabrication technologies, biosensors have gained widespread application in areas such as environmental monitoring, disease diagnosis, and clinical analysis. Methods: A systematic review of biosensor technologies, including enzyme-based, optical, electrochemical, and nucleic acid biosensors, was conducted. Peer-reviewed articles published between 2003 and 2024 were retrieved using databases like PubMed, Scopus, and Google Scholar; of the 278 identified studies, 92 satisfied the inclusion criteria and were examined. Particular attention was paid to fabrication techniques, including microfluidics, photolithography, inkjet printing, wax printing, and plasma treatment, and how they influenced the performance of the biosensor. Results: Advances in technology have created ultra-sensitive biosensors for wastewater analysis, continuous glucose monitoring, and COVID-19 detection. Multiplexing capacity was improved for high-throughput, real-time testing through microfluidic integration. Low-cost production techniques like laser cutting and wax printing enhanced affordability and scalability without sacrificing sensitivity. Discussion: The results demonstrate how biosensors may now be made smaller, more affordable, and capable of real-time monitoring due to contemporary production processes. This study shows that, in contrast to previous research, new techniques not only improve sensitivity and specificity but also provide greater accessibility of biosensor platforms for environmental and medical uses. Conclusion: Advances in fabrication strategies are transforming biosensor development and deployment. Future directions should focus on enhancing biocompatibility, integrating AI-based data analytics, and creating wearable biosensors for continuous health monitoring and environmental surveillance.