A Novel 3D-Printed Flow Cell Design for In Operando Disposable Printed Electrode Replacement: Improving Continuous Methylene Blue Determination

Using disposable screen-printed electrodes faces major challenges when attempting to monitor a continuous process, especially in systems where there is pronounced adsorption, fouling, degradation, or in cases of irreversible electrochemical reactions. Methylene Blue (MB) exhibits some therapeutic properties and is commonly used as a redox reporter in DNA sensors, but is also considered a toxic pollutant in aquatic systems. MB demonstrates strong adsorption to carbon materials, which prevents its electroanalytical determination in multiple measurements with a single electrode. Our work details direct electrochemical determination of MB with only the native carbon screen-printed working electrode as sensing material and optimization of the analytical method. In batch mode, we significantly improved sensitivity and interelectrode reproducibility by introducing a prepolarization step, but successive measurements in lower concentrations were not feasible due to strong adsorption. A fully customizable, modular flow cell was 3D printed to allow in operando replacement of the planar screen-printed three-electrode system after measurement during continuous flow. As confirmed by mechanical properties testing, the rigid polyacrylate upper section of the flow cell provides structural stability, combined with a flexible TPU lower section which enables effortless sensor hot swapping and effective sealing during flow. With an optimized hot swapping flow detection method, MB was detected via square wave voltammetry with a sensitivity of 65.59 µA/µM and a calculated LOD of 7.75 nM, which outperforms similar systems from the literature. We envisage this approach can be integrated into low-cost continuous environmental monitoring systems or in-line quality control, especially in flow chemistry synthesis.