Recent advances in nanofabrication strategies for biosensors: from precision nanopatterning to scalable, flexible, and AI-assisted manufacturing
Abstract
Nanofabrication has become central to the development of high-performance biosensors by enabling precise control over sensing interfaces, enhanced signal transduction, and integration across optical, electrochemical, microfluidic, and wearable platforms. This review examines the evolution of biosensor nanofabrication from deterministic top-down patterning toward scalable and integrated manufacturing strategies. Top-down approaches, including electron-beam lithography, focused ion beam milling, nanoimprint lithography, reactive ion etching, and laser-based fabrication, are discussed alongside replication and transfer processes, soft lithography, lithography-free plasmonic structuring, and additive three-dimensional fabrication. Bottom-up strategies based on nanoparticle assembly, DNA nanotechnology, block-copolymer and nanoporous templating, and stimuli-responsive materials are further considered as routes to programmable nanoscale organization and functional biointerfaces. Particular attention is given to flexible and wearable biosensors, where substrate mechanics, conductive-interface fabrication, textile integration, epidermal microfluidics, packaging, power management, and wireless communication introduce manufacturing requirements beyond conventional rigid devices. Across these approaches, the review emphasizes that analytical sensitivity alone is insufficient for translation; nanoscale precision must be accompanied by reproducibility, scalable processing, stable biofunctionalization, antifouling performance, packaging, storage stability, and device-level quality control. Emerging AI-assisted fabrication and process optimization strategies are also discussed as tools for linking manufacturing parameters with structural and analytical performance. Overall, the review provides a manufacturing-oriented perspective on how hybrid nanofabrication strategies can bridge high-performance laboratory biosensors with reproducible, scalable, and application-ready sensing systems.
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BibTeX
@article{avci2026recent,
title = {{Recent advances in nanofabrication strategies for biosensors: from precision nanopatterning to scalable, flexible, and AI-assisted manufacturing}},
author = {Meryem Beyza Avci and Furkan Kocer and Seda Nur Topkaya and Konstantinos Papatryfonos and Arif Cetin},
journal = {Nanotechnology},
year = {2026},
month = oct,
doi = {10.1088/1361-6528/aeb131},
url = {https://hal.science/hal-05850492v1},
note = {CC BY},
}
RIS
TY - JOUR
TI - Recent advances in nanofabrication strategies for biosensors: from precision nanopatterning to scalable, flexible, and AI-assisted manufacturing
AU - Meryem Beyza Avci
AU - Furkan Kocer
AU - Seda Nur Topkaya
AU - Konstantinos Papatryfonos
AU - Arif Cetin
PY - 2026
DA - 2026/10/21
JO - Nanotechnology
DO - 10.1088/1361-6528/aeb131
UR - https://hal.science/hal-05850492v1
AB - Nanofabrication has become central to the development of high-performance biosensors by enabling precise control over sensing interfaces, enhanced signal transduction, and integration across optical, electrochemical, microfluidic, and wearable platforms. This review examines the evolution of biosensor nanofabrication from deterministic top-down patterning toward scalable and integrated manufacturing strategies. Top-down approaches, including electron-beam lithography, focused ion beam milling, nanoimprint lithography, reactive ion etching, and laser-based fabrication, are discussed alongside replication and transfer processes, soft lithography, lithography-free plasmonic structuring, and additive three-dimensional fabrication. Bottom-up strategies based on nanoparticle assembly, DNA nanotechnology, block-copolymer and nanoporous templating, and stimuli-responsive materials are further considered as routes to programmable nanoscale organization and functional biointerfaces. Particular attention is given to flexible and wearable biosensors, where substrate mechanics, conductive-interface fabrication, textile integration, epidermal microfluidics, packaging, power management, and wireless communication introduce manufacturing requirements beyond conventional rigid devices. Across these approaches, the review emphasizes that analytical sensitivity alone is insufficient for translation; nanoscale precision must be accompanied by reproducibility, scalable processing, stable biofunctionalization, antifouling performance, packaging, storage stability, and device-level quality control. Emerging AI-assisted fabrication and process optimization strategies are also discussed as tools for linking manufacturing parameters with structural and analytical performance. Overall, the review provides a manufacturing-oriented perspective on how hybrid nanofabrication strategies can bridge high-performance laboratory biosensors with reproducible, scalable, and application-ready sensing systems.
SN - 0957-4484
SN - 1361-6528
ER -