We present a chip-based extended nano-Coulter counter
(XnCC) that
can detect nanoparticles affinity-selected from biological samples
with low concentration limit-of-detection that surpasses existing
resistive pulse sensors by 2–3 orders of magnitude. The XnCC
was engineered to contain 5 in-plane pores each with an effective
diameter of 350 nm placed in parallel and can provide high detection
efficiency for single particles translocating both hydrodynamically
and electrokinetically through these pores. The XnCC was fabricated
in cyclic olefin polymer (COP) via nanoinjection molding to allow
for high-scale production. The concentration limit-of-detection of
the XnCC was 5.5 × 103 particles/mL, which was a 1,100-fold
improvement compared to a single in-plane pore device. The application
examples of the XnCC included counting affinity selected SARS-CoV-2
viral particles from saliva samples using an aptamer and pillared
microchip; the selection/XnCC assay could distinguish the COVID-19(+)
saliva samples from those that were COVID-19(−). In the second
example, ovarian cancer extracellular vesicles (EVs) were affinity
selected using a pillared chip modified with a MUC16 monoclonal antibody.
The affinity selection chip coupled with the XnCC was successful in
discriminating between patients with high grade serous ovarian cancer
and healthy donors using blood plasma as the input sample.