Cited by 100Neuroscience and Neural EngineeringEEG and Brain-Computer InterfacesAnalog and Mixed-Signal Circuit Design

A flexible three-dimensional electrode mesh: An enabling technology for wireless brain–computer interface prostheses

Open access
Xiang, Zhuolin, Liu, Jingquan, Lee, Chengkuo·2016·Microsystems & Nanoengineering

Abstract

The neural interface is a key component in wireless brain–computer prostheses. In this study, we demonstrate that a unique three-dimensional (3D) microneedle electrode on a flexible mesh substrate, which can be fabricated without complicated micromachining techniques, is conformal to the tissues with minimal invasiveness. Furthermore, we demonstrate that it can be applied to different functional layers in the nervous system without length limitation. The microneedle electrode is fabricated using drawing lithography technology from biocompatible materials. In this approach, the profile of a 3D microneedle electrode array is determined by the design of a two-dimensional (2D) pattern on the mask, which can be used to access different functional layers in different locations of the brain. Due to the sufficient stiffness of the electrode and the excellent flexibility of the mesh substrate, the electrode can penetrate into the tissue with its bottom layer fully conformal to the curved brain surface. Then, the exposed contact at the end of the microneedle electrode can successfully acquire neural signals from the brain.

AI snapshot

Written from the paper’s full text.

TL;DR

A flexible three-dimensional SU-8 microneedle electrode array on a polyimide mesh was fabricated by drawing lithography and tested for neural recording. The device conformed to curved rat brain surfaces, penetrated tissue, and recorded spontaneous and evoked neural signals.

Key findings

  • Microneedle length was controlled by the SU-8 pillar diameter defined by the 2D mask, not by baking temperature or drawing speed; measured lengths ranged from 400 μm to 2.2 mm, with design capability from 400 μm up to 3 mm.
  • The flexible substrate had a bending energy of only 0.89 mJ m⁻², lower than reported adhesion energy for wet interfaces, supporting conformal attachment to curved brain. Tensile testing showed reversible linear behavior below 1.9% strain and tensile strength below 4.03 N.
  • Buckling force increased with microneedle diameter up to 300 μm, then saturated and decreased for larger diameters.
  • In vivo, of 16 microneedle electrodes across 5 implantations, at least 7 out of 16 sites (43%) successfully recorded neural activity; hind-paw stimulation with 2 mA increased local field potentials, with larger changes in the central array region where primary somatosensory cortex was located.

Methods

  • Fabrication used an Al sacrificial layer, photosensitive polyimide base and top layers, Cr/Au traces, SU-8 pillars, drawing lithography to form sharp tips, sputtered Au, parylene-C insulation with openings only at electrode tips, and anodic metal dissolution for release.
  • Mechanical characterization used an Instron Microtester 5848: tensile tests at 10 mm min⁻¹, buckling tests at 20 μm s⁻¹, microneedle diameters from 200 to 400 μm in 25-μm intervals, and ten samples per group for buckling and length-error measurements.
  • In vivo testing used male Sprague-Dawley rats under ketamine/Pentothal anesthesia, craniotomy, maltose-assisted insertion, a tungsten cortical reference, and an RZ5D BioAmp Processor; spontaneous activity and evoked local field potentials after 2-mA hind-paw stimulation were recorded.

Limitations

  • The paper states no dedicated limitations of its own approach; it discusses limitations of prior 3D microneedle fabrication and rigid-substrate interfaces.
  • Evident from the text: in vivo validation was acute in rats, with only 5 implantations and a recording yield of at least 7/16 sites (43%); chronic implantation and long-term stability were not demonstrated, although the conclusion proposes the platform for monitoring chronic neural activity.

Model-written summary. Check it against the paper before relying on it.

Integrity signals

Registry

Crossref · 10.1038/micronano.2016.12

Cites

40 of 40 references verified0 citation errors · 0 not checkable

Statistics

Nothing to recompute.

Claims the paper makes

0 of 22 cited sources checked · 0 supported · 0 flagged

  • Findingreasoning

    The length of the 3D microneedle electrodes can be changed from 400 μm up to 3 mm via the design of the 2D mask pattern.

    “the length of these 3D microneedle electrodes also can be changed from 400 μm up to 3 mm via the design of the 2D mask pattern.”
    Quote in the paperSubstantial claim
  • Findingown data

    The microneedle electrodes fabricated using this approach were from 400 μm to 2.2 mm in length.

    “The measurement data indicate that the microneedle electrodes fabricated using this approach were from 400 μm to 2.2 mm in length.”
    Quote in the paperNot a substantial claim
  • Findingown data

    A 3D microneedle electrode on a flexible mesh substrate can be fabricated without complicated micromachining techniques.

    “we demonstrate that a unique three-dimensional (3D) microneedle electrode on a flexible mesh substrate, which can be fabricated without complicated micromachining techniques, is conformal to the tissues with minimal invasiveness.”
    • Also stated in: § Introduction · boosted
      “we demonstrate that a unique 3D microneedle electrode on a flexible substrate, which can be fabricated without complicated micromachining techniques, is conformal to tissues with minimal invasiveness”
    • Also stated in: § Conclusions · boosted
      “This work successfully demonstrated that a 3D flexible microneedle electrode made of biocompatible materials could be fabricated using a new drawing lithography technology.”
    Quote in the paperSubstantial claim
  • Findingreasoning

    The profile of a 3D microneedle electrode array is determined by the design of a 2D pattern on the mask.

    “In this approach, the profile of a 3D microneedle electrode array is determined by the design of a two-dimensional (2D) pattern on the mask, which can be used to access different functional layers in different locations of the brain.”
    • Also stated in: § Length dependency of the microneedle electrodes · hedged
      “the microneedle electrode length could be determined by the drawn cylindrical liquid column, R0, which was determined by the mask pattern for the SU-8 pillars.”
    • Also stated in: § Conclusions · plain
      “Using 2D designed patterns on a mask, the profile of the 3D microneedle electrode array can be controlled to access different functional layers in the brain.”
    Quote in the paperSubstantial claim
  • Findingown data

    The microneedles have sufficient stiffness for successful penetration into brain tissue.

    “To prove that the microneedles have sufficient stiffness for successful penetration, the buckling force was tested.”
    • Also stated in: § Conclusions · plain
      “The polymer-based microneedle electrode is strong enough to successfully penetrate the brain tissue and communicate with the neural system with its low impedance contacts.”
    Quote in the paperSubstantial claim
  • May combine two claims. 8
  • Classified as probably not a substantial claim. 2
  • May combine two claims.

    Findingcitation

    The post-processing step induced a crosslink in the SU-8 to enhance the stiffness of the device and removed possible toxic leachants increasing its biocompatibility.

    “This post-processing step not only induced a crosslink in the SU-8 to enhance the stiffness of the device but also removed the possible toxic leachants increasing its biocompatibility34.”
    Quote in the paperNot a substantial claim0 of 1 sources checked
    • cites [34] Vernekar VN, Cullen DK, Fogleman N et al. SU-8 2000 rendered cytocompatible for neuronal bioMEMS applications. Journal of Biomedical Materials Research 2009; 89: 138–151. source

      Not checked in the free run.

  • May combine two claims.

    Findingown data

    The in vivo tests on rats show that the flexible microneedle electrode can be implanted successfully into a brain with a curved surface and record neural signals.

    “The in vivo tests on rats show that the flexible microneedle electrode can be implanted successfully into a brain with a curved surface and record neural signals.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingcitation

    The total bending energy of the device's flexible substrate was 0.89 mJ m−2, which is smaller than the reported adhesion energy for wet interfaces.

    “On the basis of this mathematic model, the total bending energy of the device’s flexible substrate was only 0.89 mJ m−2, which is smaller than the reported adhesion energy for wet interfaces38.”
    Quote in the paperSubstantial claim0 of 1 sources checked
    • cites [38] Chaudhury MK, Whitesides GM . Direct measurement of interfacial interactions between semispherical lenses and flat sheets of poly (dimethylsiloxane) and their chemical derivatives. Langmuir 1991; 7: 1013–1025. source

      Not checked in the free run.

  • May combine two claims.

    Findingreasoning

    The buckling force of the fabricated microneedle electrode initially increased with diameter, saturated when the diameter was larger than 300 μm, and then decreased with further increase in diameter.

    “Initially, when the diameter was increased, the buckling force of the fabricated microneedle electrode also increased. However, when the diameter of the microneedle electrode was larger than 300 μm, its buckling force tended to be saturated. Further increasing the diameter decreased the buckling force.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingown data

    When the strain was >1.9%, the neural ribbon was in an irreversibly deformed range, and the device formed a neck in its central region.

    “When the strain was >1.9%, the neural ribbon was in an irreversibly deformed range, and the device formed a neck in its central region.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingown data

    When the strain was <1.9%, the polyimide neural ribbon was in a reversible linear range, and the corresponding tensile strength was <4.03 N.

    “When the strain was <1.9%, the polyimide neural ribbon was in a reversible linear range, and the corresponding tensile strength was <4.03 N.”
    Quote in the paperSubstantial claim
  • Classified as probably not a substantial claim.

    Premisecitation

    Selectively recruiting different layers in the peripheral nerve results in a graded force generation in various muscle groups.

    “For instance, selectively recruiting different layers in the peripheral nerve results in a graded force generation in various muscle groups23–25.”
    Quote in the paperSubstantial claim0 of 3 sources checked
    • cites [23] Yu H, Xiong W, Zhang H et al. A parylene self-locking cuff electrode for peripheral nerve stimulation and recording. Journal of Microelectromechanical Systems 2014; 23: 1025–1035. source

      Not checked in the free run.

    • cites [24] Fisher LE, Tyler DJ, Triolo RJ . Optimization of selective stimulation parameters for multi-contact electrodes. Journal of NeuroEngineering and Rehabilitation 2013;. 10: 25. source

      Not checked in the free run.

    • cites [25] Raspopovic S, Capogrosso M, Badia J et al. Experimental validation of a hybrid computational model for selective stimulation using transverse intrafascicular multichannel electrodes. IEEE Transactions on Neural Systems and Rehabilitation Engineering 2012; 20: 395–404. source

      Not checked in the free run.

  • May combine two claims.

    Interpretationreasoning

    The deformed flexible substrate will be conformal to the curved brain and will not induce shear forces on the brain tissue via the inserted microneedles.

    “The deformed flexible substrate will be conformal to the curved brain and will not induce shear forces on the brain tissue via the inserted microneedles (Figure 5c).”
    • Also stated in: § Conclusions · plain
      “Due to its excellent flexibility and mesh structure, the deformed substrate is conformal to the curved brain and will not induce any shear force on the brain tissue via the inserted microneedles.”
    Quote in the paperSubstantial claim
  • Probably not a substantial claim: may not pass S3 (load-bearing).

    Premisecitation

    The Utah Slanted Electrode Array (USEA) provides comprehensive access to multiple independent motor nerves.

    “The Utah Slanted Electrode Array (USEA) was proposed to provide comprehensive access to multiple independent motor nerves27,28”
    Quote in the paperNot a substantial claim0 of 2 sources checked
    • cites [27] Branner A, Stein RB, Normann RA . Selective stimulation of cat sciatic nerve using an array of varying-length microelectrodes. Journal of Neurophysiology 2001; 85: 1585–1594. source

      Not checked in the free run.

    • cites [28] Wark HAC, Sharma R, Mathews KS et al. A new high-density (25 electrodes/mm2) penetrating microelectrode array for recording and stimulating sub-millimeter neuroanatomical structures. Journal of Neural Engineering 2013; 10: 045003. source

      Not checked in the free run.

  • May combine two claims.

    Premisecitation

    Stimulation in different layers of the cerebral cortex induces various activations of neuronal subtypes and their complex connection to subcortical regions, which leads to diverse cognition, sensory perception and motor control.

    “Stimulation in different layers of the cerebral cortex induces various activations of neuronal subtypes and their complex connection to subcortical regions, which leads to diverse cognition, sensory perception and motor control26.”
    Quote in the paperSubstantial claim0 of 1 sources checked
    • cites [26] Lebedev MA, Nicolelis MAL . Brain-machine interfaces: Past, present and future. Trends in Neurosciences 2006; 29: 536–546. source

      Not checked in the free run.

10 of 10
  • The paper relies on this without support.

    The microneedle length can be extended beyond the demonstrated 2.2 mm without limitation.

    “it can be applied to different functional layers in the nervous system without length limitation”
    “the length of these 3D microneedle electrodes also can be changed from 400 μm up to 3 mm via the design of the 2D mask pattern.”
  • The paper relies on this without support.

    The fabricated microneedle electrodes can record neural signals from different functional layers of the brain.

    “it can be applied to different functional layers in the nervous system without length limitation”
    “Using 2D designed patterns on a mask, the profile of the 3D microneedle electrode array can be controlled to access different functional layers in the brain.”
  • The paper relies on this without support.

    The inserted microneedles do not cause significant damage to brain tissue.

    “is conformal to the tissues with minimal invasiveness”
    “is conformal to tissues with minimal invasiveness”
3 of 3

Claims other papers make about this one

Each is checked against this paper’s own text: does it say what the citing paper says it does?

Self-check

Percentages, sums and reported differences re-computed from the paper’s own numbers.

  • Recording-site percentage does not match the count

    Minor

    Seven of 16 sites is 43.75%, which rounds to 44%, not the reported 43%.

    Reported 43 · recomputed 43.75

1 of 1

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Authors
Xiang, Z., Liu, J., & Lee, C.
Affiliations
  • National University of Singapore (SG)
  • Shanghai Jiao Tong University (CN)
Corresponding author
Lee, Chengkuo
Venue
Microsystems & Nanoengineering
Published
2016-05-23
Volume
2
Issue
1
Pages
16012-16012
ISSN
2055-7434 (ISSN-L)
OpenAlex
W2401080870
Cited by
100
References
40
Citations by year
2026: 11 · 2025: 11 · 2024: 9 · 2023: 3 · 2022: 8 · 2021: 18 · 2020: 10 · 2019: 10 · 2018: 11 · 2017: 7 · 2016: 2
FWCI
5.61
Type
journal article
Language
en
Open access
Locations
  • Microsystems & Nanoengineering (publishedVersion, cc-by)
  • PubMed Central (publishedVersion, cc-by)
  • PubMed (publishedVersion)
  • National University of Singapore (submittedVersion)
Funders
National Research Foundation (R-263-000-A27-281)
Topics
  • Life Sciences › Neuroscience › Cellular and Molecular Neuroscience › Neuroscience and Neural Engineering
  • Life Sciences › Neuroscience › Cognitive Neuroscience › EEG and Brain-Computer Interfaces
  • Physical Sciences › Engineering › Biomedical Engineering › Analog and Mixed-Signal Circuit Design
Keywords
neural prostheses, biomaterials, conformal electrodes, neural signal acquisition

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