Laser-Scribed Graphene on PDMS for Flexible Wearable Sweat Biosensors with Multiplexed Sensing Capability

Sweat is a valuable biofluid for non-invasive health monitoring, as it contains electrolytes, metabolites, and organic compounds that can correlate with blood levels, making it highly attractive for wearable sensing. Building on advances in low-cost, portable electrochemical sensors, sweat analysis enables tracking of hydration status, metabolic stress, and energy availability via key markers such as sodium, potassium, lactate, and glucose. In the sports context, such wearable platforms can support performance optimization and recovery by assessing fluid loss and electrolyte balance in real time. Here, a multiplexed wearable sweat patch is developed to simultaneously monitor temperature, pH, ammonium, sodium, and sweat rate. The integrated platform demonstrates sensitivities of 10.1 mV/ln[NH4+], 9.1 mV/ln[K+], 1.11 mV/ln[Na+], 14 mV/pH, 0.19% °C−1, and approximately −1.0 mA (mL/min)−1 for sweat rate, with stable signals and linear calibration responses over relevant physiological ranges. The sensor is implemented on a lightweight, biocompatible laser-scribed graphene on a PDMS substrate suitable for prolonged skin contact and mechanical deformation. In addition, a custom PDMS adhesive patch with optimized suction-cup microstructures is engineered to improve skin adhesion under both dry and wet conditions. Finally, the design of the platform was inspired by an adaptive cycling marathon across Saudi Arabia, where an earlier prototype of a wearable patch was deployed for real-time monitoring during a 30-day campaign.