Isolation and Purification-Free Digital Single-Small Extracellular Vesicle Biosensing with Scalable Plasmonic Arrays

Recent advances in plasmonic biosensing and imaging have enabled label-free analysis of single biological nanoparticles. We previously developed PlAsmonic NanOapeRture lAbel-free iMAging (PANORAMA) for isolation and purification-free, digital counting and precise localization of small extracellular vesicles (sEVs), with complementary fluorescence interrogation of surface and intravesicular biomarkers for quantitative molecular profiling. The fact that no isolation and purification or isolation is needed represents a crucial advantage because various specificity, efficiency, and time-consumption issues hinder quantitatively reproducible extraction of sEVs from biological fluids. PANORAMA achieves ultrahigh refractive-index sensitivity through arrayed gold nanodisks on invisible substrates (AGNIS) fabricated by nanosphere lithography (NSL). However, despite its simplicity and low cost, NSL is frequently constrained by poor large-area uniformity, which hinders scalable fabrication. Here, we introduce nanosphere settling lithography (NSSL) as an alternative to the gold-standard Langmuir-Blodgett trough (LBT) process, enabling highly uniform, large-area monolayers with reduced process stringency. AGNIS fabricated via NSSL exhibits high refractive-index sensitivity with low spatial variability across 60 mm x 24 mm substrates, sufficient for 60-well in standard 384-well plate format. The platform demonstrates exquisite sensitivity through PANORAMA digital counting and sizing of 25, 50, and 100 nm polystyrene beads, as well as single-vesicle characterization of sEVs derived from H460 lung cancer cells. For the first time, combined PANORAMA and fluorescence imaging enables quantitative analysis of microRNA-21 (miR-21) expression in sEVs to identify "cancer-suspicious" sub-population from liver cancer patient plasma in an unbiased fashion allowing both highly sensitive detection of individual sEVs and simultaneous molecular profiling. Collectively, NSSL enables uniform, high-performance plasmonic biosensing over large areas, providing a scalable and economical pathway for high-throughput, digital single-sEV analysis and translational liquid biopsy applications.