Design and manufacturing of a surface plasmon resonance sensor based on inkjet 3D printing for simultaneous measurements of refractive index and temperature

In this work, a surface plasmon resonance (SPR) multiparameter sensor for simultaneous determination of refractive index and temperature was manufactured through a novel and low-cost approach. Monitoring these parameters is useful when biosensors are developed by exploiting SPR phenomena. A polymer planar optical structure was realized via inkjet 3D printing, by using photo-curable resins having tailored refractive index for device’s core and cladding, respectively. The multiparameter sensor was fully designed, manufactured, and experimentally tested to check the numerical analyses run on a preliminary phase. In such a way, a temperature resolution equal to about 0.5°C and a refractive index resolution equal to about 2 × 10−4 RIU (refractive index unit) were obtained. Next, even a quality control analysis of the 3D printed surface was carried out by following a novel approach that relies on the profile monitoring technique, with the aim to evaluate the suitability of the design and the geometric accuracy control. In addition, thanks to the cost analysis performed through a properly model, it was proved that the multiparameter sensor designed, manufactured, and tested satisfies the low-cost requirements, being the estimated cost ~ 23 €, which is an absolutely competitive cost if compared with other traditional sensors. In the end, even the performance of the sensor in terms of bulk sensitivity (equal to about 900nm/RIU) resulted to be higher than similar devices already presented in the state-of-the-art, thus proving the validity of the developed SPR multiparameter sensor both in economic and performance terms. Graphical abstract: [Figure not available: see fulltext.]