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Method Article

Fabrication of Flat-Interface Nerve Electrodes for Recording Neural Activity

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July 8th, 2025

In This Article

Abstract

Source: Dweiri, Y. M., et al. Fabrication of high contact-density, flat-interface nerve electrodes for recording and stimulation applications. J. Vis. Exp. (2016)

This video demonstrates the fabrication of a flat nerve-wrapping electrode. It showcases the integration of shielding metal and precise polymer layering for an effective recording surface. The process involves attaching, curing, trimming, and cutting polymer layers for optimal nerve contact and accurate signal recording.

Protocol

1. Electrode Components Preparation

  1. Gather four electrode components that require precision cutting (laser cutting was used; please refer to the Materials List) before manufacturing. These components are (Figure 1):
    Contacts array frame: This frame comprises a 125 µm thick Polyether ether ketone (PEEK) sheet. It covers the entire width of the cuff and holds the middle contacts and has serpentine-shaped edges (Figure 1B). The middle contacts are wrapped in the guide channels; hence the exposed width of the contacts is limited by the width of the channels and the spacing is determined by the spac....

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Results

Nerve cuff electrode assembly diagram and surgical placement; dimensions in millimeters.
Figure 1: Overview of the FINE and its Components. A) FINE in the open position and the four main building components that require precision cut. These components are: Contacts array frame (I), the middle contacts strips (II), the reference contact.......

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Disclosures

No conflicts of interest declared.

Materials

List of materials used in this article
NameCompanyCatalog NumberComments
Platinum-Iridium foilAlfa Aesar4180290%Platinum Iridium
DFT wiresFort Wayne Metals35N LT-DFT-28%Ag
Lead connectorOmnetics Connector CorporationMCS-27-SS
Silicone sheetSpeciality Silicon Fabricator0.005"x12"x12" Silicone SheetHigh durometer, vulcanized
Polyether ether ketone (PEEK) sheetPeek-Optima0.005 sheet LT3 grade
polyester stabelizing meshSurgicalmeshPETKM2002
Silicon tubing (0.04" I.D. 0.085" O.D.)Silcon Medical/NewAge Industries.2810458
Outer shielding layerAlfa Aesar, A Johnson MattheyMFCD00003436 (11391)Gold foil, 0.004" thick
Transparency sheetAPOLLOAPOCG7060
Ultrasonic bath cleanerTerra Universal2603-00A-220
Isotemp standard lab ovenFisher Scientific13247637G
Optical microscopeFisher Scientific15-000-101
TweezersTechnik18049USA (2A-SA)
Surgical blade handlesAspen Surgical Products371031
Base frameMcMaster-Carr9785K411
Support beamMcMaster-Carr9524K359
Two parts siliconeNusilMED 4765
Soldering FluxSRA Soldering ProductsFLS71
Tape3M Healthcare1535-0 (SKUMMM15350H)Paper, hypoallergenic surgical tape
Spot welding machineUnitek125 Power Supply with 101F Welding Head
Laser cutting platformUniversal Laser SystemsPLS6.150D150 watts laser

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