In Situ Performance Monitoring of Electrochemical Oxygen and Hydrogen Peroxide Sensors in an Additively Manufactured Modular Microreactor.

Miniaturized and microstructured reactors in process engineering are essential for a more decentralized, flexible, sustainable, and resilient chemical production. Modern, additive manufacturing methods for metals enable complex reactor-geometries, increased functionality, and faster design iterations, a clear advantage over classical subtractive machining and polymer-based approaches. Integrated microsensors allow online, in situ process monitoring to optimize processes like the direct synthesis of hydrogen peroxide. We developed a modular tube-in-tube membrane reactor fabricated from stainless steel via 3D printing by laser powder bed fusion of metals (PBF-LB/M). The reactor concept enables the spatially separated dosage and resaturation of two gaseous reactants across a membrane into a liquid process medium. Uniquely, we integrated platinum-based electrochemical sensors for the online detection of analytes to reveal the dynamics inside the reactor. An advanced chronoamperometric protocol combined the simultaneous concentration measurement of hydrogen peroxide and oxygen with monitoring of the sensor performance and self-calibration in long-term use. We demonstrated the highly linear and sensitive monitoring of hydrogen peroxide and dissolved oxygen entering the liquid phase through the membrane. Our measurements delivered important real-time insights into the dynamics of the concentrations in the reactor, highlighting the power of electrochemical sensors applied in process engineering. We demonstrated the stable continuous measurement over 1 week and estimated the sensor lifetime for months in the acidic process medium. Our approach combines electrochemical sensors for process monitoring with advanced, additively manufactured stainless steel membrane microreactors, supporting the power of sensor-equipped microreactors as contributors to the paradigm change in process engineering and toward a greener chemistry.

Advanced electrochemical potential monitoring for improved understanding of electrical neurostimulation protocols.

Objective.Current-controlled neurostimulation is increasingly used in the clinical treatment of neurological disorders and widely applied in neural prostheses such as cochlear implants. Despite its importance, time-dependent potential traces of electrodes during microsecond-scale current pulses, especially with respect to a reference electrode (RE), are not precisely understood. However, this knowledge is critical to predict contributions of chemical reactions at the electrodes, and ultimately electrode stability, biocompatibility, and stimulation safety and efficacy.Approach.We assessed the electrochemistry of neurostimulation protocolsin vitrowith Pt microelectrodes from millisecond (classical electroanalysis) to microsecond (neurostimulation) timescales. We developed a dual-channel instrumentation amplifier to include a RE in neurostimulation setups. Uniquely, we combined potential measurements with potentiostatic prepolarization to control and investigate the surface status, which is not possible in typical stimulation setups.Main results.We thoroughly validated the instrumentation and highlighted the importance of monitoring individual electrochemical electrode potentials in different configurations of neurostimulation. We investigated electrode processes such as oxide formation and oxygen reduction by chronopotentiometry, bridging the gap between milli- and microsecond timescales. Our results demonstrate how much impact on potential traces the electrode's initial surface state and electrochemical surface processes have, even on a microsecond scale.Significance.Our unique use of preconditioning in combination with stimulation reveals that interpreting potential traces with respect to electrode processes is misleading without rigorous control of the electrode's surface state. Especiallyin vivo, where the microenvironment is unknown, simply measuring the voltage between two electrodes cannot accurately reflect the electrode's state and processes. Potential boundaries determine charge transfer, corrosion, and alterations of the electrode/tissue interface such as pH and oxygenation, particularly in long-termin vivouse. Our findings are relevant for all use-cases of constant-current stimulation, strongly advocating for electrochemicalin situinvestigations in many applications like the development of new electrode materials and stimulation methods.

In situ stability monitoring of platinum thin-film electrodes for neural interfaces in the presence of proteins.

The long-term stability of platinum electrodes is a key factor that determines the life-time of biomedical devices, such as implanted neural interfaces like brain stimulation or recording electrodes, cochlear implants, and biosensors. The downsizing of such devices relies on the usage of microfabricated thin-film electrodes. In order to determine and investigate the causal degradation processes for platinum electrodes, it is essential to use potential-controlled experiments, which allow selectable polarization of the electrode without exceeding the water stability window boundaries. Therefore, the surface processes and redox reactions occurring at the electrode are known at all times. In this study, we present the continuous in situ monitoring of platinum-based thin-film electrodes along their complete life cycle in neutral pH with and without the presence of proteins. The usage of chronoamperometry for electrode aging, monitoring of surface processes and the tracking of analyte redox processes, together with cyclic voltammetry to determine the complete amount of surface charge, allows a reliable quantification of fundamental degradation processes. We found that platinum dissolution is primarily driven by the formation and removal of Pt oxide. Despite the significantly lowered charge transfer, the presence of proteins did not prevent material loss or increase electrode lifetime. These results should be considered when interpreting results from current-controlled methods as typically used for neural interfaces. Clinical Relevance- All clinically relevant applications of microelectrodes, ranging from cell culture over diagnostics to in vivo use, involve the presence of proteins. Detailed and fundamental insight into electrode stability in the presence of proteins is therefore essential for successful clinical translation of neural interface technologies.

Electrochemical microelectrode degradation monitoring:in situinvestigation of platinum corrosion at neutral pH.

Objective. The stability of platinum and other noble metal electrodes is critical for neural implants, electrochemical sensors, and energy sources. Beyond the acidic or alkaline environment found in most electrochemical studies, the investigation of electrode corrosion in neutral pH and chloride containing electrolytes is essential, particularly regarding the long-term stability of neural interfaces, such as brain stimulation electrodes or cochlear implants. In addition, the increased use of microfabricated devices demands the investigation of thin-film electrode stability in combination with electrode performance.Approach. We developed a procedure of electrochemical methods for continuous tracking of electrode degradationin situover the complete life cycle of platinum thin-film microelectrodes in a unique combination with simultaneous chemical sensing. We used chronoamperometry and cyclic voltammetry to measure electrode surface and analyte redox processes, together with accelerated electrochemical degradation.Main results.We compared degradation between thin-film microelectrodes and bulk electrodes, neutral to acidic pH, different pulsing schemes, and the presence of the redox active species oxygen and hydrogen peroxide. Results were confirmed by electrochemical impedance spectroscopy, as well as mechanical profilometry and microscopy to determine material changes on a nanometer scale. We found that electrode degradation is mainly driven by repeated formation and removal of the platinum surface oxide, also within the electrochemical stability window of water. There was no considerable difference between thin-film micro- and macroscopic bulk electrodes or in the presence of reactive species, whereas acidic pH or extending the potential window led to increased degradation.Significance.Our results provide valuable fundamental information on platinum microelectrode degradation under conditions found in biomedical applications. For the first time, we employed a unified method to report quantitative data on electrode degradation up to a defined endpoint. Our method is a widely applicable framework for comparative long-term studies of electrode micro-/nanomaterial, sensor and neural interface stability.