3D Printing in the Design of Potentiometric Sensors: A Review of Techniques, Materials, and Applications

The integration of 3D printing into the development of potentiometric sensors has revolutionized sensor fabrication by enabling customizable, low-cost, and rapid prototyping of analytical devices. Techniques like fused deposition modeling (FDM) and stereolithography (SLA) allow researchers to produce different sensor parts, such as electrode housings, solid contacts, reference electrodes, and even microfluidic systems. This review explains the basic principles of potentiometric sensors and shows how 3D printing helps solve problems faced in traditional sensor manufacturing. Benefits include smaller size, flexible shapes, the use of different materials in one print, and quick production of working prototypes. However, some challenges still exist—like differences between prints, limited chemical resistance of some materials, and the long-term stability of sensors in real-world conditions. This paper overviews recent examples of 3D-printed ion-selective electrodes and related components and discusses new ideas to improve their performance. It also points to future directions, such as better materials and combining different manufacturing methods. Overall, 3D printing is a powerful and growing tool for developing the next generation of potentiometric sensors for use in healthcare, environmental monitoring, and industry.