Scalable manufacturing of flexible electronics via screen printing for biomedical applications

Unmet Need: Flexible and stretchable electrodes face challenges in commercial adoption due to complex and costly microfabrication processes

Current manufacturing processes for flexible biomedical electronics are complex and expensive, typically requiring cleanroom microfabrication. While other methods have been explored, none cover the full fabrication process. This invention streamlines production workflows for flexible biomedical electronics via a fully screen-printable manufacturing process. The method leverages commercially available inks and produces electrodes that maintain excellent mechanical compliance. Electrodes maintain fine detail crucial to producing reliable electronics. This invention supports low-cost production at scale, holding great economic potential for wearable electronics and medical devices.

The Technology: Demonstrate excellent mechanical compliance during deformation, while simplifying manufacturing processes

Fully screen-printed electrodes are achieved by adjusting the viscosity of existing Polyimide inks with a thixotropic material. Inventors developed a fully screen-printable manufacturing process for skin-conformable multilayer electrodes. The electrodes successfully demonstrate excellent mechanical compliance, with the ability to tolerate deformation such as twisting, bending, and stretching. This technology is a 2024 Commercialization Gap Fund recipient.

Applications:

• Biomedical sensors for EKG, EEG, EOG, vital signs, pediatric/neonatal monitoring, etc.
• Wearable electronics including smartwatches, fitness trackers, and electronic textiles
• Skin-mountable therapeutics and drug delivery systems

Advantages:

• Low-cost manufacturing
• Excellent mechanical compliance
• Easy printing process
• Adapts easily to manufacturing at scale