Sweat analysis offers non-invasive real-time on-body measurement for wearable sensors. However, there are still gaps in current developed sweat-sensing devices (SSDs) regarding the concerns of mixing fresh and old sweat and real-time measurement, which are the requirements to ensure accurate the measurement of wearable devices. This review paper discusses these limitations by aiding model designs, features, performance, and the device operation for exploring the SSDs used in different sweat collection tools, focusing on continuous and non-continuous flow sweat analysis. In addition, the paper also comprehensively presents various sweat biomarkers that have been explored by earlier works in order to broaden the use of non-invasive sweat samples in healthcare and related applications. This work also discusses the target analyte’s response mechanism for different sweat compositions, categories of sweat collection devices, and recent advances in SSDs regarding optimal design, functionality, and performance.

Wearable technology, such as electronic components integrated into clothing or worn as accessories, is becoming increasingly prevalent in fields like healthcare and biomedical monitoring. These devices allow for continuous monitoring of important biomarkers for medical diagnosis, monitoring of physiological health, and evaluation. However, an open-source wearable potentiostat is a relatively new technology that still faces several design limitations such as short battery lifetime, bulky size, heavy weight, and the requirement for a wire for data transmission, which affects comfortability during long periods of measurement. In this work, an open-source wearable potentiostat device named We-VoltamoStat is developed to allow interested parties to use and modify the device for creating new products, research, and teaching purposes. The proposed device includes improved and added features, such as wireless real-time signal monitoring and data collection. It also has an ultra-low power consumption battery estimated to deliver 15 mA during operating mode for 33 h and 20 min and 5 mA during standby mode for 100 h without recharging. Its convenience for wearable applications, tough design, and compact size of 67x54x38 mm make it suitable for wearable applications. Cost-effectiveness is another advantage, with a price less than 120 USD. Validation performance tests indicate that the device has good accuracy, with an R2 value of 0.99 for linear regression of test accuracy on milli-, micro-, and nano-Ampere detection. In the future, it is recommended to improve the design and add more features to the device, including new applications for wearable potentiostats.

Wearable sweat-sensing devices hold significant potential for non-invasive, continuous health monitoring. However, challenges such as ensuring data accuracy, sensor reliability, and measurement stability persist. This study presents the development of a wearable system for the real-time monitoring of human sweat sodium levels, addressing these challenges through the integration of a novel microfluidic chip and a compact potentiostat. The microfluidic chip, fabricated using hydrophilic materials and designed with vertical channels, optimizes sweat flow, prevents backflow, and minimizes sample contamination. The developed wearable potentiostat, as a measurement device, precisely measures electrical currents across a wide dynamic range, from nanoamperes to milliamperes. Validation results demonstrated accurate sodium concentration measurements ranging from 10 mM to 200 mM, with a coefficient of variation below 4% and excellent agreement with laboratory instruments (intraclass correlation = 0.998). During physical exercise, the device measured a decrease in sweat sodium levels, from 101 mM to 67 mM over 30 min, reflecting typical physiological responses to sweating. These findings confirm the system’s reliability in providing continuous, real-time sweat sodium monitoring. This work advances wearable health-monitoring technologies and lays the groundwork for applications in fitness optimization and personalized hydration strategies. Future work will explore multi-biomarker integration and broader clinical trials to further validate the system’s potential.