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Wearable sweat biosensors offer compelling opportunities for improved personal health monitoring and non-invasive measurements of key biomarkers. Inexpensive device fabrication methods are necessary for scalable manufacturing of portable, disposable, and flexible sweat sensors. Furthermore, real-time sweat assessment must be analyzed to validate measurement reliability at various sweating rates. Here, we demonstrate a “smart bandage” microfluidic platform for cortisol detection and continuous glucose monitoring integrated with a synthetic skin. The low-cost, laser-cut microfluidic device is composed of an adhesive-based microchannel and solution-processed electrochemical sensors fabricated from inkjet-printed graphene and silver solutions. An antibody-derived cortisol sensor achieved a limit of detection of 10 pM and included a low-voltage electrowetting valve, validating the microfluidic sensor design under typical physiological conditions. To understand effects of perspiration rate on sensor performance, a synthetic skin was developed using soft lithography to mimic human sweat pores and sweating rates. The enzymatic glucose sensor exhibited a range of 0.2 to 1.0 mM, a limit of detection of 10 μM, and reproducible response curves at flow rates of 2.0 μL min −1 and higher when integrated with the synthetic skin, validating its relevance for human health monitoring. These results demonstrate the potential of using printed microfluidic sweat sensors as a low-cost, real-time, multi-diagnostic device for human health monitoring.
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This content will become publicly available on July 1, 2026
A micro-to-macroscale and multi-method investigation of human sweating dynamics
Sweat secretion and evaporation from the skin dictate the human ability to thermoregulate and thermal comfort in hot environments and impact skin interactions with cosmetics, textiles and wearable electronics/sensors. However, sweating has mostly been investigated using macroscopic physiological methods, leaving micro-to-macroscale sweating dynamics unexplored. We explore these processes by using a coupled micro-imaging and transport measurement approach used in engineering studies of phase change processes. Specifically, we used a comprehensive set of ‘macroscale’ physiological measurements (ventilated capsule sweat rate (SR), galvanic skin conductance and dielectric epidermis hydration) complemented by three microscale imaging techniques (visible light, midwave infrared and optical coherence tomography imaging). Inspired by industrial jet cooling devices, we also explore an ‘air jet’ (versus cylindrical) capsule for measuring SR. To enable near-simultaneous application of these methods, we studied forehead sweating dynamics of six supine subjects undergoing passive heating, cooling and secondary heating. The relative dynamics of the physiological measurements agree with prior observations and can be explained using imaged microscale sweating dynamics. This comprehensive study provides new insights into the biophysical dynamics of sweating onset and following cyclic porewise, transition and filmwise sweating modes and highlights the roles of stratum corneum hydration, salt deposits and microscale hair.
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- Award ID(s):
- 2214152
- PAR ID:
- 10617824
- Publisher / Repository:
- Royal Society
- Date Published:
- Journal Name:
- Journal of The Royal Society Interface
- Volume:
- 22
- Issue:
- 228
- ISSN:
- 1742-5662
- Subject(s) / Keyword(s):
- sweating
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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