Viruses are no longer used only for vaccines: they have become essential tools across a growing range of biopharmaceutical applications. Yet producing them at clinical quality remains complex, costly and error-prone, and is still controlled with sparse, offline measurements. Real-time biosensors can change this by monitoring viral activity directly during production.
To manufacture these sensorized platforms, we developed high-resolution two-photon polymerization (2PP) printing with integrated real-time imaging and AI-driven defect detection, enabling “first-time-right” production of the complex, nanometre-scale scaffolds the sensors are built on.