Polymer-Based Microfluidic Devices for Point-of-Care Diagnostics: A Comprehensive Review

Abstract

Background/objectives: Polymer-based microfluidic platforms have emerged as a critical area for the development of point-of-care (POC) diagnostics, driven by the need for rapid, low-cost, and portable testing solutions. This review examines how these systems utilize polymeric substrates to integrate complex laboratory processes into compact, user-friendly devices for healthcare and environmental applications. Methods: This review examines various polymeric substrates, including polydimethylsiloxane, thermoplastics, paper, and hydrogels. It also discusses diverse fabrication approaches ranging from soft lithography, hot embossing, and laser ablation to three-dimensional printing and paper-based patterning besides detection strategies spanning optical and electrochemical sensing, surface plasmon resonance, and smartphone-based readouts. Results: The unique properties of polymers, including optical transparency, biocompatibility, tunable surface chemistry, and cost-effectiveness, support the development of diagnostic assays for infectious diseases, cancer biomarkers, and environmental monitoring. Advances in fabrication and detection strategies have improved device sensitivity, portability, and scalability. However, there remain challenges related to material selection, standardization, reproducibility, and regulatory translation. Conclusions: Despite these challenges, continued advances in novel polymers, sustainable materials, and integrated “sample-to-answer” systems are expected to accelerate the development of polymer microfluidic devices for POC diagnostics. Nevertheless, overcoming regulatory, manufacturing standardization and clinical validation challenges is essential for their widespread clinical adoption. Ultimately, polymer microfluidic devices have the potential to support decentralized diagnostics and personalized medicine while improving healthcare accessibility.