Novel fabrication technique for development of polymer-based microsensor arrays for molecular diagnostics

An innovative production technique is described for the low-cost production of arrays of interdigitated electrode (IDE) structures. The resulting polymer chips form the basis of a new type of diagnostic device allowing for the impedimetric detection of either hybridisation or immuno-affinity binding of antibody-antigen combinations. Sensitivity of the IDEs is maximised by focusing the field of sensitivity to the molecules of interest by lowering the electrode dimensions and spacing to the sub-micron region. This has been achieved using a unique combination of state-of-the-art micro-structuring of polymers and the directionality of metal-deposition by evaporation. Subsequently, polymer based arrays of IDEs with micron to sub-micron electrode widths can be realised using a single metallisation step, completely omitting any sophisticated photolithography.