Silky Liquid Metal Electrodes for On-Skin Health Monitoring

Next generation on-skin electrodes will require soft, flexible, and gentle materials to provide both high-fidelity sensing and wearer comfort. However, many commercially available on-skin electrodes lack these key properties due to their use of rigid hardware, harsh adhesives, uncomfortable support structures, and poor breathability. To address these challenges, this work presents a new device paradigm by joining biocompatible electrospun spider silk with printable liquid metal to yield an incredibly soft and scalable on-skin electrode that is strain-tolerant, conformable, and gentle on-skin. These electrodes, termed silky liquid metal (SLiM) electrodes, are found to be over five times more breathable than commercial wet electrodes, while the silk's intrinsic adhesion mechanism allows SLiM electrodes to avoid the use of harsh artificial adhesives, potentially decreasing skin irritation and inflammation over long-term use. Finally, the SLiM electrodes provide comparable impedances to traditional wet and other liquid metal electrodes, offering a high-fidelity sensing alternative with increased wearer comfort. Human subject testing confirmed the SLiM electrodes ability to sense electrophysiological signals with high fidelity and minimal irritation to the skin. The unique properties of the reported SLiM electrodes offer a comfortable electrophysiological sensing solution especially for patients with pre-existing skin conditions or surface wounds.

In Situ Formation of Conductive Epidermal Electrodes Using a Fully Integrated Flexible System and Injectable Photocurable Ink

In situ fabrication of wearable devices through coating approaches is a promising solution for the fast deployment of wearable devices and more adaptable devices for different sensing demands. However, heat, solvent, and mechanical sensitivity of biological tissues, along with personal compliance, pose strict requirements for coating materials and methods. To address this, a biocompatible and biodegradable light-curable conductive ink and an all-in-one flexible system that conducts in situ injection and photonic curing of the ink as well as monitoring of biophysiological information have been developed. The ink can be solidified through spontaneous phase changes and photonic cured to achieve a high mechanical strength of 7.48 MPa and an excellent electrical conductivity of 3.57 × 10⁵ S/m. The flexible system contains elastic injection chambers embedded with specially designed optical waveguides to uniformly dissipate visible LED light throughout the chambers and rapidly cure the ink in 5 min. The resulting conductive electrodes offer intimate skin contact even with the existence of hair and work stably even under an acceleration of 8 g, leading to a robust wearable system capable of working under intense motion, heavy sweating, and varied surface morphology. Similar concepts may lead to various rapidly deployable wearable systems that offer excellent adaptability to different monitoring demands for the health tracking of large populations.

Cryo-Transferred Ultrathin and Stretchable Epidermal Electrodes

A simple cryo-transfer method to fabricate ultrathin, stretchable, and conformal epidermal electrodes based on a combination of silver nanowires (AgNWs) network and elastomeric polymers is developed. This method can temporarily enable the soft elastomers with much higher elastic modulus and dimensional contraction through exploiting their glass-transition behaviors. During this process, a much higher Von Mises stress can be loaded on AgNWs than usual, and the generated strong grip force can facilitate the complete transfer of AgNWs. Afterward, the thawed AgNWs and elastomer composites quickly recover to their soft state at room temperature. The obtained ultrathin and soft electrode with a thickness of 8.4 µm and transmittance of 90.8% at a sheet resistance of 13.2 Ω sq^-1 can tolerate a stretching strain of 70% and 50 000 repeated bending cycles, which meets rigorous requirements of epidermal applications. The as-prepared epidermal electrodes are effective and comfortable for electrophysiological signal monitoring, and while showing excellent performance exceeding the commercialized gel electrodes.

Solution-Processed Submicron Free-Standing, Conformal, Transparent, Breathable Epidermal Electrodes

Long-term, real-time, and comfortable epidermal electronics are of great practical importance for healthcare monitoring and human-machine interaction. However, traditional physiological signal monitoring confined by the specific clinical sites and unreliability of the epidermal electrodes leads to great restrictions on its application. Herein, we constructed a solution-processed submicron (down to 230 nm), free-standing, breathable sandwich-structured hybrid electrode composed of a silver nanowire network with a conductive polymer film, which is conformal, water-permeable, and noninvasive to the skin while achieving good signal acquisition ability. The free-standing hybrid electrode is prepared via an in situ capillary force lift-off process and can be transferred onto complex surfaces. The whole process is a complete solution process that facilitates large-area preparation and application. The light-weight hybrid electrodes exhibit high optical transmittance, high electrical conductivity, and high gas/ion permeability. When the hybrid electrodes are attached onto the skin, the imperceptible films show high conformality with low electrical impedance, thus exhibiting significantly improved electrocardiology and electromyogram signal monitoring performance compared to that of the commercial gel electrodes.

Nanofiber-Reinforced Silver Nanowires Network as a Robust, Ultrathin, and Conformable Epidermal Electrode for Ambulatory Monitoring of Physiological Signals

Extremely soft and thin electrodes with high skin conformability have potential applications in wearable devices for personal healthcare. Here, a submicrometer thick, highly robust, and conformable nanonetwork epidermal electrode (NEE) is reported. Electrospinning of polyamide nanofibers and electrospraying of silver nanowires are simultaneously performed to form a homogeneously convoluted network in a nonwoven way. For a 125 nm thick NEE, a low sheet resistance of ≈4 Ω sq^-1 with an optical transmittance of ≈82% is achieved. Due to the nanofiber-based scaffold that undertakes most of the stress during deformation, the electric resistance of the NEE shows very little variation; less than 1.2% after 50 000 bending cycles. The NEE can form a fully conformal contact to human skin without additional adhesives, and the NEE shows a contact impedance that is over 50% lower than what is found in commercial gel electrodes. Due to conformal contact even under deformation, the NEE proves to be a stable, robust, and comfortable approach for measuring electrocardiogram signals, especially when a subject is in motion. These features make the NEE promising for use in the ambulatory measurement of physiological signals for healthcare applications.