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bioRxiv · 10.1101/2025.03.29.646121

Advancing EEG Biosensing: Novel Scalable Production of Platinum-Silicon Microneedles

Amir, M.·Ding, R.·Rusli, N. I.·Vercooren, N.·Ceyssens, F.·Kuznetsova, N.·Bertrand, A.·Kraft, M.·Taurino, I.
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Abstract

This study presents the development and analysis of a silicon microneedle electrode array fabricated using a streamlined, two-step approach for enhanced bio-signal recording applications. Numerical simulations with COMSOL Multiphysics were employed to optimize the microneedle array design, focusing on mechanical stability and minimizing skin-electrode impedance. Structural analysis identified needle lengths between 500 m and 700 m as optimal for mechanical robustness, with critical load factors indicating a high resistance to buckling under applied forces. Optimal needle spacing was determined to prevent inter-needle interference and ensure effective skin penetration. Proof-of-concept electroencephalography testing confirmed that the microneedles achieved reliable bio-signal recording, comparable to traditional wet electrodes, while offering advantages such as reduced preparation time and improved user comfort. This work establishes a simple and cleanroom-compatible, scalable method for fabricating platinum-coated silicon microneedle arrays, advancing the development of wearable, user-friendly biopotential monitoring devices.

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Amir, M., Ding, R., Rusli, N. I., Vercooren, N., Ceyssens, F., Kuznetsova, N., Bertrand, A., Kraft, M., Taurino, I.. 2025-04-03. Advancing EEG Biosensing: Novel Scalable Production of Platinum-Silicon Microneedles. https://doi.org/10.1101/2025.03.29.646121

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