Direct management and assessment of metal film properties applied to polymer microneedle (MN) biosensors remains difficult due to constraints inherent to their morphology. By simplifying the three-dimensional structure of MNs and adjusting the deposition time, different thicknesses of Au films were deposited on the UV-cured polymer planar and MN substrates. Several properties relevant to the biosensing of the Au films grown on the polymer surfaces were investigated. The results demonstrate the successful deposition of pure and stable Au nanoparticles onto the surface of UV-curable polymer materials. Initially, Au islands formed within the first minute of deposition; however, as the sputtering time extended, these islands transformed into Au nanoparticle films and disappeared. The hydrophilicity of the surface remains unchanged, while the surface resistance of the thin film decreases with increasing thickness, and the adhesion to the substrate decreases as the thickness increases. In short, a sputtering time of 5-6 min results in Au films with a thickness of 100-200 nm, which exhibit exceptional comprehensive biosensing performance. Additionally, MNs made of Au/UV-curable polymers and produced using magnetron sputtering maintain their original shape, enhance their mechanical characteristics, and gain new functionalities. The Au/UV-curable polymer MNs exhibited remarkable electrode performance despite being soaked in a 37 °C PBS solution for 14 days. These discoveries have important implications in terms of decreasing the dependence on valuable metals in MN biosensors, lowering production expenses, and providing guidance for the choice and design of materials for UV-curable polymer MN metallization films.
Keywords: Au films; Polymer microneedles; biosensing properties; magnetron sputtering; metallization.