Mark D. Poliks | Binghamton University: Can printed electronics on flimsy plastic survive being brutally creased and bent hundreds of times?
00:06:03 - 00:07:37
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Can printed electronics on flimsy plastic survive being brutally creased and bent hundreds of times?
The adjustable lead sets for this vital sign monitor are constructed from thermoplastic polyurethane (TPU), a flexible and stretchable plastic. The design incorporates multiple printed layers, with the conductive traces being the most critical. A key challenge is ensuring these printed circuits remain functional despite the flimsy nature of the substrate, which can be easily bent, stretched, and creased during handling and application, especially in rugged field conditions.
To accommodate different body sizes and movements, the design incorporates serpentine elastic connectors within the leads. These structures, which can be made with printed conductors or by integrating fine wires, allow for significant stretchability, enabling a "pull-to-fit" functionality. However, this added flexibility introduces more complex interconnects and potential points of failure, making robust design and manufacturing paramount to ensure consistent electrical performance.
Extensive reliability testing was conducted to validate the design's durability. Standard bending tests on INSTRON and MTS systems showed the leads were robust to hundreds of cycles. More impressively, extreme crease tests—where the leads were sharply folded up to 50 times in the same location or held in a creased position for 24 hours—demonstrated that the laminated structure was exceptionally resilient, proving the viability of this printed electronics approach for demanding, real-world applications.
In this short video, you can learn:
* How serpentine structures enable stretchability in printed circuits on flexible substrates.
* The multi-layer lamination process used to create robust, encapsulated flexible leads.
* The surprising results of extreme crease and bend testing on printed silver conductors.
📋 **Clip Abstract** This clip details the mechanical design and rigorous reliability testing of printed electronic leads on flexible TPU substrates. It reveals that through careful design and lamination, these systems can withstand hundreds of bend cycles and extreme creasing, proving their viability for rugged applications.
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#PrintedElectronics, #TPUsubstrate, #SerpentineStructures, #MultiLayerLamination, #MedicalDevices, #WearableElectronics
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00:10:21 - 00:11:23
How do you prove a flexible medical patch can survive the intense vibrations of an emergency aircraft transport?
How do you prove a flexible medical patch can survive the intense vibrations of an emergency aircraft transport?
A critical requirement for any device intended for aeromedical use is the ability to withstand severe environmental stressors without compromising performance. The system was subjected to the six-mode human vibration test, a standard protocol that simulates the intense, multi-axis vibrations experienced during the transport of patients in aircraft. This demanding validation is essential to ensure that the vital sign readings remain accurate and uninterrupted in a high-stakes emergency environment.
The testing was performed both at the Air Force Research Laboratory and in-house at Binghamton University, using specialized vibration systems. The flexible patches were subjected to vibrations in both horizontal and vertical configurations to comprehensively assess their response. This rigorous methodology aimed to identify any potential failure modes or signal degradation caused by the mechanical stress of a simulated flight.
The results demonstrated a key advantage of the flexible, low-modulus design. The lightweight patch did not couple with the severe vibrations; in fact, it effectively damped them. The system's performance was unaffected, and the only electrical noise detected was an artifact from the vibration table's motors interfering with the sensitive ECG signal, not a failure of the device itself. This proved the intrinsic robustness of the flexible hybrid electronics approach for harsh-environment applications.
In this short video, you can learn:
* The specific requirements of the six-mode human vibration test for aeromedical devices.
* Why low-modulus, lightweight flexible electronics are inherently robust to intense vibration.
* How printed electronic systems on soft substrates can act as vibration dampers, a key advantage over rigid electronics.
📋 **Clip Abstract** This segment focuses on the validation of a flexible vital sign monitor for the extreme environment of aeromedical transport. It details the six-mode human vibration test and reveals the key finding that the low-modulus patch is not only immune to intense vibration but can even act as a damper.
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#FlexibleElectronics, #VibrationTesting, #AeromedicalDevices, #VibrationDamping, #WearableElectronics, #MedicalDevices
00:12:36 - 00:14:45
Can you use printed electronics with painless microneedles to detect stress and infection biomarkers directly from your skin?
Can you use printed electronics with painless microneedles to detect stress and infection biomarkers directly from your skin?
This work moves beyond electrophysiology to biochemical sensing by sampling interstitial fluid (ISF), the fluid found in the spaces around cells. Using an array of painless microneedles that barely penetrate the skin, the patch can access this ISF, which is a rich source of biomarkers for monitoring conditions like stress (via cortisol) or physical exertion (via lactate) without drawing blood. This approach opens the door to continuous, minimally invasive monitoring of the body's biochemistry.
The device architecture is a prime example of flexible hybrid electronics, integrating several key components into a single patch. It combines the disposable microneedle array with all-printed electrochemical sensor cells. This sensor portion is connected to a reusable electronics module containing a miniaturized, lab-on-a-chip potentiostat from Analog Devices, which performs the complex electrochemical analysis directly on the body.
The platform supports multiple sensing technologies. While the lactate sensor is a relatively straightforward electrochemical sensor, the cortisol sensor represents a more advanced approach. It is a bio-recognition sensor that uses an aptamer—a single-stranded DNA or RNA molecule—that specifically binds to cortisol. This binding event triggers a measurable change in electrical current, allowing for highly specific and sensitive detection of the target biomarker.
In this short video, you can learn:
* How painless microneedles can sample biomarker-rich interstitial fluid from below the skin.
* The flexible hybrid electronics architecture that integrates microneedles, printed sensors, and advanced silicon ICs.
* The use of aptamers as bio-recognition elements for creating highly specific printed sensors for molecules like cortisol.
📋 **Clip Abstract** This clip explores a cutting-edge application of flexible electronics: a patch that uses painless microneedles to sample interstitial fluid for biochemical analysis. It details the system's architecture and the development of printed electrochemical sensors for biomarkers like lactate and cortisol, including an advanced aptamer-based sensor.
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#PainlessMicroneedles, #FlexibleHybridElectronics, #PrintedElectrochemicalSensors, #AptamerSensors, #WearableElectronics, #BiomedicalSensing