Soft, flexible electrodes tailored to the brain’s surface may improve neural monitoring and treatment of neurodegenerative diseases. Unlike rigid, one-size-fits-all sensors, the team developed a 3D-printing method to create stretchable electrodes that match each brain’s unique shape.
Using MRI data from 21 patients, the researchers created detailed brain models and customized electrode designs before printing both. Reported in Advanced Materials, the results showed these tailored electrodes fit better than conventional ones while remaining effective and biocompatible, including in animal tests.
Personalized Neural Interfaces for Brain Differences
The human brain’s folds—formed through gyrification into ridges (gyri) and grooves (sulci)—vary significantly between individuals, even though overall patterns are similar. These variations affect how well standard, one-size-fits-all electrodes can interface with the brain. Tao Zhou noted that brain structure varies with age, size, and sex, underscoring the need for personalized neural interfaces.
The electrodes are primarily made from a soft, water-rich material called hydrogel, allowing them to better match the brain’s delicate tissue and unique shape. The researchers also incorporated a honeycomb-inspired design that provides both flexibility and durability while staying inexpensive and fast to produce.
According to Zhou, this structure lowers the electrodes’ stiffness without compromising strength, while also reducing the amount of material needed—cutting production time, cost, and environmental impact.
From MRI Scans to Custom-Fit Brain Electrodes
The process begins with an MRI scan of a patient’s brain, which is used in a finite element analysis to generate a precise simulation of its structure. This simulation is converted into a 3D model, where software is used to design electrodes tailored to the brain’s specific folds and contours.
Hydrogel electrodes are 3D printed via direct ink printing to monitor neural signals. Tested on 21 brain models, they showed precise fit, while offering faster, cheaper production than traditional clean-room methods.
Compared to conventional designs, the hydrogel-based electrodes more closely match the brain’s surface, enabling near-perfect capture of its electrical signals. Zhou explained that their soft, stretchable material can conform to delicate brain tissue without causing harm—unlike rigid electrodes that may damage it.
Softer Design Improves Contact and Signal Quality
This softness allows for tighter, more stable contact with the brain, resulting in clearer and more reliable signal monitoring. The design also avoids interfering with fluid movement around the brain, an essential function that many traditional electrodes can disrupt. As Zhou noted, tailoring electrodes to an individual’s brain significantly boosts both fit and signal quality.
To evaluate performance, the team tested the electrodes on rat brains for 28 days. The devices showed no immune response or performance loss, while reliably recording electrical and physiological signals.
Zhou believes this 3D-printing approach could pave the way for large-scale production of patient-specific bioelectrodes. While such devices are typically used for monitoring, the team aims to explore their potential in treating neurological conditions. Future work will refine the technology for specific diseases and test it in clinical settings with patients.
Read the original article on:medicalxpress
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