With the rapid growth of emerging point-of-use (POU)/point-of-care (POC) detection technologies, miniaturized sensors for the real-time detection of gases and airborne pathogens have become essential to fight pollution, emerging contaminants, and pandemics. However, the low-cost development of miniaturized gas sensors without compromising selectivity, sensitivity, and response time remains challenging. Microfluidics is a promising technology that has been exploited for decades to overcome such limitations, making it an excellent candidate for POU/POC. However, microfluidic-based gas sensors remain a nascent field. In this review, the evolution of microfluidic gas sensors from basic electronic techniques to more advanced optical techniques such as surface-enhanced Raman spectroscopy to detect analytes is documented in detail. This paper focuses on the various detection methodologies used in microfluidic-based devices for detecting gases and airborne pathogens. Non-continuous microfluidic devices such as bubble/droplet-based microfluidics technology that have been employed to detect gases and airborne pathogens are also discussed. The selectivity, sensitivity, advantages/disadvantages vis-a-vis response time, and fabrication costs for all the microfluidic sensors are tabulated. The microfluidic sensors are grouped based on the target moiety, such as air pollutants such as carbon monoxide and nitrogen oxides, and airborne pathogens such as E. coli and SARS-CoV-2. The possible application scenarios for the various microfluidic devices are critically examined.

Microfluidic devices are constructed from polydimethylsiloxane (PDMS) due to their biocompatibility, fabrication ease, well-established protocols, and simplicity. PDMS-based microfluidic devices are constructed by (i) applying liquid PDMS to a negative mold (usually a silicon or 3D-printed mold) and (ii) curing the PDMS with heat exposure over a set time period. Unreacted resin monomers in 3D-printed molds prevent PDMS from fully curing, resulting in improper channel formation in PDMS and reducing the PDMS device’s efficacy. An in-house protocol that uses SU-8 as a “non-stick” coating on 3D-printed molds facilitates the successful casting of PDMS. Contact angle, surface profile, optical profile, and force testing prove that PDMS cast from SU-8-treated molds resembles pristine PDMS, unlike PDMS cast from untreated molds. Further, this method is generalized to commercial 3D prints using different 3D printing resins. To demonstrate this technique’s viability in microfluidic devices, a microfluidic tree using PDMS from treated 3D prints shows vibrant colors and clear lines. This is absent from an untreated PDMS.

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We present a new methodological approach for the assessment of the susceptibility of Rhodococcus erythropolis strains from specific sampling sites in response to increasing heavy metal concentration (Cu2+, Ni2+, and Co2+) using the droplet-based microfluid technique. All isolates belong to the species R. erythropolis identified by Sanger sequencing of the 16S rRNA. The tiny step-wise variation of metal concentrations from zero to the lower mM range in 500 nL droplets not only provided accurate data for critical metal ion concentrations but also resulted in a detailed visualization of the concentration-dependent response of bacterial growth and autofluorescence activity. As a result, some of the isolates showed similar characteristics in heavy metal tolerance against Cu2+, Ni2+, and Co2+. However, significantly different heavy metal tolerances were found for other strains. Surprisingly, samples from the surface soil of ancient copper mining areas supplied mostly strains with a moderate sensitivity to Cu2+, Ni2+, and Co2+, but in contrast, a soil sample from an excavation site of a medieval city that had been covered for about eight centuries showed an extremely high tolerance against cobalt ion (up to 36 mM). The differences among the strains not only may be regarded as results of adaptation to the different environmental conditions faced by the strains in nature but also seem to be related to ancient human activities and temporal partial decoupling of soil elements from the surface. This investigation confirmed that microfluidic screening offers empirical characterization of properties from same species which has been isolated from sites known to have different human activities in the past.