Laser-scribed micro/nanostructures modified surfaces for electrochemical sensors: From fundamentals to applications

Laser scribing has emerged as a transformative technique in surface nanostructuring, redefining the fabrication of high-performance electrochemical sensors. Leveraging the superior precision characteristics, it enables rapid and sustainable generation of nanoscale features on diverse materials to significantly enhance the overall sensitivity, selectivity, and stability of a sensor. The direct laser structuring process offers tunable porosity, controlled defect density, and enhanced charge transfer kinetics, making laser-engraved electrodes highly effective for broader molecular sensing applications. This article explores the fundamental mechanisms of laser-induced nanostructuring, exploring the diverse morphologies achievable through this technique as well as subsequent nanoengineering on them and their impact on sensor functionality. It also examines the integration of laser-engraved sensors with microfluidic systems, highlighting their potential in multiplexed point-of-care diagnostics and lab-on-a-chip devices. In contrast to all such advancements, this review also addresses the major challenges that pose critical barriers to commercialization of this technique. It also discusses future prospects for overcoming them, including the development of alternative substrate materials and optimization of laser parameters. By harnessing the power of laser engraving, researchers are pushing the boundaries of sensor capabilities, paving the way for more accurate, reliable, and versatile sensing devices. These innovations hold immense promise for applications in healthcare, environmental monitoring, and biomedical research, marking a significant step forward in the field of nanotechnology and biosensing.