Introduction

Research has increasingly focused on novel methods in neurology. Findings from many studies are constantly enabling new approaches to novel therapies [1]. This wide range of research findings will enable the development of novel therapies for neurological diseases. To researchers all over the world equipment tailored to their studies is essential.

Here we present the °AirRay Electrode Technology which enables the development of electrodes that meet the expectations for the use in unique studies in the research of neurological diseases.

Methods/Materials

We developed manufacturing methods for high resolution electrode arrays made from the traditional implant materials PtIr and medical grade silicone. These materials are layered on top of each other while each new layer is micropatterned with a laser. As a result, flat arrays are produced that resembles printed circuit boards made from medical grade silicone and PtIr electrode contacts, conduction lines and weld pads. Medical grade wires are welded to the pads and the welds are sealed with silicone adhesive. The flat electrode arrays can be 3D-shaped to a peripheral nerve cuff by laminating them to the inside of a silicone tubing.

Results

The electrode arrays are typically between 100um and 500um thin, the metal thickness is between 10um to 25um, very much depending on the application. Flat devices (grid or strip electrode arrays) have been used acutely and chronically in animal research as well as acutely and sub-chronically in man. Cuffs have been used in acute and chronic animal studies as well as in acute human studies for fascicle-selective nerve stimulation as well as neural blocking and recording.

Discussion

In contrast to manual lead manufacturing, laser micromachining provides a high degree of automation combined with a very high reproducibility and processing precision. Electrode arrays can be very thin, soft and flexible and can have contacts ranging from 50um to some mm in diameter.

Conclusions

Micromachining of traditional implant materials such as silicone rubber and noble metal foil allows to produce very soft and flexible, high definition neural electrode arrays as electrical interface for the peripheral and central nervous system in a semi-automated production process. The technology permits the making of human implantable devices as approved by the FDA in early 2019.

References

[1]: Famm, Kristoffer, et al. "Drug discovery: a jump-start for electroceuticals." Nature 496.7444 (2013): 159.